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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Type IV failure in weldment of creep resistant ferritic alloys: I. Micromechanical origin of creep strain localization in the heat affected zone

Creep strength enhanced ferritic (CSEF) steels containing 9-12wt% chromium have been extensively used in fossil-fuel-fired power plants. Despite their excellent creep resistance at high temperatures, premature failures (especially Type IV cracking) are often found in the fine-grained heat affected zone (HAZ) or intercritical HAZ of the welded components. This failure mode is preceded by the strain localization in the HAZ, as measured by the Digital Image Correlation (DIC) technique. The present work aims to develop a finite-element based computational method to determine the micromechanical and microstructural origin of the strain localization phenomenon. We construct a two-dimensional digital microstructure based on the actual microstructure of ferritic steel weldments by using the Voronoi-tessellation method, to account for the effects of its large grain-size gradients. A mechanism-based finite element method is developed for modeling the high temperature deformation resulting from a synergy of thermally activated dislocation movements, diffusional flow and grain boundary sliding. The numerical results agree well with the strain measurements by our DIC technique, particularly revealing the effect of pre-welding tempering on the evolution of strain localization in HAZ of creep resistant steel weldments. It is found that the diffusional creep with dependence on grain sizes, dislocation creep with dependence on material strength, and more importantly, grain boundary sliding, contribute synergistically to the creep strain accumulation in the HAZ, and their relative degree of significance is quantified. The creep rupture life will be investigated in the companion paper.

36 MATERIALS SCIENCE↗
DOE OSTI2016

A dissolution-precipitation mechanism is at the origin of concrete creep in moist environments

Long-term creep (i.e., deformation under sustained load) is a significant material response that needs to be accounted for in concrete structural design. However, the nature and origin of concrete creep remain poorly understood and controversial. Here, we propose that concrete creep at relative humidity ≥ 50%, but fixed moisture content (i.e., basic creep), arises from a dissolution-precipitation mechanism, active at nanoscale grain contacts, as has been extensively observed in a geological context, e.g., when rocks are exposed to sustained loads, in liquid-bearing environments. Based on micro-indentation and vertical scanning interferometry data and molecular dynamics simulations carried out on calcium–silicate–hydrate (C–S–H), the major binding phase in concrete, of different compositions, we show that creep rates are correlated with dissolution rates—an observation which suggests a dissolution-precipitation mechanism as being at the origin of concrete creep. C–S–H compositions featuring high resistance to dissolution, and, hence, creep are identified. Analyses of the atomic networks of such C–S–H compositions using topological constraint theory indicate that these compositions present limited relaxation modes on account of their optimally connected (i.e., constrained) atomic networks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2011

Creep and Environmental Effects on High Temperature Creep-Fatigue Behavior of Alloy 617

Alloy 617 is the leading candidate material for Intermediate Heat Exchanger (IHX) of a Very High Temperature Reactor (VHTR), expected to have an outlet temperature as high as 950 C. System start-ups and shut-downs as well as power transients will produce low cycle fatigue (LCF) loadings of components. Acceptance of Alloy 617 in Section III of the ASME Code for nuclear construction requires a detailed understanding of the creep-fatigue behavior in both air and impure helium, representative of the VHTR primary coolant. Strain controlled LCF tests including hold times at maximum tensile strain were conducted at total strain range of 0.3% in air at 950 C. Creep-fatigue testing was also performed in a simulated VHTR impure helium coolant for selected experimental conditions. The fatigue resistance decreased when a hold time was added at peak tensile stress, consistent with the observed change in fracture mode from transgranular to intergranular with introduction of a tensile hold. Increases in the tensile hold time, beyond 180 sec, was not detrimental to the creep-fatigue resistance. Grain boundary damage in the form of grain boundary cracking was present in the bulk of the creep-fatigue specimens. This bulk cracking was quantified and found to be similar for hold times of up to 1800 sec consistent with the saturation in failure lives and rapid stress relaxation observed during the creep portion of the creep-fatigue cycle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2011

Dislocation decorrelation and relationship to deformation microtwins during creep of a y' precipitate strengthened Ni-based superalloy

The evolution of microtwins during high temperature creep deformation in a strengthened Ni-base superalloy has been investigated through a combination of creep testing, TEM characterization, theoretical modeling and computer simulation. Experimentally, microtwin nucleation sources were identified and their evolution was tracked by characterizing the deformation substructure at different stages of the creep deformation. Initially, deformation is highly localized around stress concentrators such as carbides, borides and serrated grain boundaries, which act as sources of a/2<110> matrix type dislocations. Due to microstructural effects such as fine channels between particles and low matrix stacking fault energies, the a/2<110> matrix dislocations dissociate into a/6<112> Shockley partials, which were commonly observed to be decorrelated from one another, creating extended intrinsic stacking faults in the matrix. As deformation progress further, microtwins form via partial dislocations cooperatively shearing both and phases on adjacent {111} glide planes. The TEM observations lead directly to an analysis of dislocation-precipitate interactions. Through phase field simulations and theoretical analysis based on Orowan looping, the important processes of dislocation dissociation and decorrelation are modeled in detail, providing comprehensive insight into the microstructural features and applied stress conditions that favor the microtwinning deformation mode in strengthened Ni-based superalloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Guideline for the Assessment of Uniaxial Creep and Creep-Fatigue Data and Models

Of primary concern to FE practitioners is a determination of which constitutive models are the “best”, capable of reproducing the mechanisms expected in an intended design accurately; as well as what experimental datasets are proper or “best” to use for fitting the constitutive parameters needed for the model(s) of interest. In addition, the inherent uncertainty in experiments and the repeatability and stability of extrapolations (for long-lived FE components) is a major concern. The goal of this project is to develop a guideline for the assessment of uniaxial creep and creep-fatigue data and models. The research objectives are RO1) develop an aggregated database of creep and creep-fatigue data for P91 steel and 316 stainless steel and perform a systematic assessment of the uncertainty and integrity of the datasets. RO2) employ the database to benchmark existing creep and creep-fatigue models to evaluate the model’s ability to predict standard and nonstandard boundary conditions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2012

Effect of exposure in steam or argon on the creep properties of Ni-based alloys: Creep properties of Ni-based alloys

Although expensive, Ni-based superalloys are of interest for the ultrasupercritical steam program because of their good creep and oxidation resistance at temperature above 700 C. However, the effect of steam oxidation on the alloy mechanical properties is unknown, and creep specimens of alloy CCA617, 740 and 230 were pre-oxidized for 2000 and 4000h in steam at 800 C before testing in air at the same temperature. Exposure in steam decreased the creep properties of alloy CCA617 compared with as fabricated material, had less of an effect on alloy 740, and did not affect alloy 230. Testing of a specimen repolished after steam exposure as well as microstructure observation indicate that the oxidation affected zone at the specimen surface is not responsible for the properties degradation. Surprisingly, a similar time anneal in an inert environment resulted in a drastic decrease of creep rupture life and an increase in the creep rate and elongation at rupture. TEM analysis revealed that the mechanical properties decrease for alloy CCA617 is related to the absence of precipitates in the grain.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Constitutive Modeling of High Temperature Uniaxial Creep-Fatigue and Creep-Ratcheting Responses of Alloy 617

Inconel Alloy 617 is a high temperature creep and corrosion resistant alloy and is a leading candidate for use in Intermediate Heat Exchangers (IHX) of the Next Generation Nuclear Plants (NGNP). The IHX of the NGNP is expected to experience operating temperatures in the range of 800 degrees - 950 degrees C, which is in the creep regime of Alloy 617. A broad set of uniaxial, low-cycle fatigue, fatigue-creep, ratcheting, and ratcheting-creep experiments are conducted in order to study the fatigue and ratcheting responses, and their interactions with the creep response at high temperatures. A unified constitutive model developed at North Carolina State University is used to simulate these experimental responses. The model is developed based on the Chaboche viscoplastic model framework. It includes cyclic hardening/softening, strain rate dependence, strain range dependence, static and dynamic recovery modeling features. For simulation of the alloy 617 responses, new techniques of model parameter determination are developed for optimized simulations. This paper compares the experimental responses and model simulations for demonstrating the strengths and shortcomings of the model.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Summary report on the mechanical testing performed at INL for creep rupture, fatigue, creep-fatigue, and aging of A709 base material

The report provides the status of the creep, fatigue, and creep-fatigue testing to conducted at Idaho National Laboratory to generate a data package to support Alloy 709 qualification in American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section III, Division 5. These tests were performed on three commercial heats of plate material. The first procured heat was manufactured by G.O. Carlson with heat number 58776. Second and third heats were fabricated by ATI Specialty Rolled Products, with heat numbers 529900 and 530843, respectively. A series of creep and cyclic specimens were fabricated from these three heats, and tests were performed. This report presents a master list of all completed and ongoing creep, fatigue, and creep fatigue tests. Cyclic properties of three commercial heats are compared. Thermal aging of three commercial heats for 3000 hours were completed in FY 2025. The thermal aging campaign to age plate material from three commercial heats up to 100,000 hours is ongoing.

36 - MATERIALS SCIENCE↗
DOE OSTI2021

Accurate Effective Stress Measures: Predicting Creep Life for 3D Stresses Using 2D and 1D Creep Rupture Simulations and Data

Operating structural components experience complex loading conditions resulting in 3D stress states. Current design practice estimates multiaxial creep rupture life by mapping a general state of stress to a uniaxial creep rupture correlation using effective stress measures. The data supporting the development of effective stress measures are nearly always only uniaxial and biaxial, as 3D creep rupture tests are not widely available. This limitation means current effective stress measures must extrapolate from 2D to 3D stress states, potentially introducing extrapolation error. In this work, we use a physics-based, crystal plasticity finite element model to simulate uniaxial, biaxial, and triaxial creep rupture. Here, we use the virtual dataset to assess the accuracy of current and novel effective stress measures in extrapolating from 2D to 3D stresses and also explore how the predictive accuracy of the effective stress measures might change if experimental 3D rupture data was available. We confirm these conclusions, based on simulation data, against multiaxial creep rupture experimental data for several materials, drawn from the literature. The results of the virtual experiments show that calibrating effective stress measures using triaxial test data would significantly improve accuracy and that some effective stress measures are more accurate than others, particularly for highly triaxial stress states. Results obtained using experimental data confirm the numerical findings and suggest that a unified effective stress measure should include an explicit dependence on the first stress invariant, the maximum tensile principal stress, and the von Mises stress.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of Creep and Oxidation on Reduced Creep-Fatigue life of Ni-based Alloy 617 at 850 C

Low cycle fatigue (LCF) and creep fatigue testing of Ni-based alloy 617 was carried out at 850 C. Compared with its LCF life, the material s creep fatigue life decreases to different extents depending on test conditions. To elucidate the microstructure-fatigue property relationship for alloy 617 and the effect of creep and oxidation on its fatigue life, systematic microstructural investigations were carried out using scanning electron microscopy, energy-dispersive X-ray spectroscopy, and electron backscatter diffraction (EBSD). In LCF tests, as the total strain range increased, deformations concentrated near high angle grain boundaries (HAGBs). The strain hold period in the creep fatigue tests introduced additional creep damage to the material, which revealed the detrimental effect of the strain hold time on the material fatigue life in two ways. First, the strain hold time enhanced the localized deformation near HAGBs, resulting in the promotion of intergranular cracking of alloy 617. Second, the strain hold time encouraged grain boundary sliding, which resulted in interior intergranular cracking of the material. Oxidation accelerated the initiation of intergranular cracking in alloy 617. In the crack propagation stage, if oxidation was promoted and the cyclic oxidation damage was greater than the fatigue damage, oxidation-assisted intergranular crack growth resulted in a significant reduction in the material s fatigue life.

Chen, Xiang↗
DOE OSTI2021

Creep, Fatigue, and Creep-Fatigue Testing of Alloy 709 Base Metal at ORNL (FY 2021)

The testing activities and research in support of ASME Code qualification of Alloy 709, an advanced austenitic steel, are being carried out at Oak Ridge National Laboratory (ORNL), Argonne National Laboratory, and Idaho National Laboratory. ORNL has been tasked to carry out a subset of the Code Case testing for creep rupture, fatigue and creep-fatigue. The focus of the FY 2021 Code Case testing on Alloy 709 base metal at ORNL includes (1) continuing the long-term creep rupture testing on ESR1100 and AOD1100; (2) adding ESR1150-AH to the creep Code Case testing matrix; and (3) continuing fatigue and creep-fatigue Code Case testing on ESR1150- AH. This report summarizes the status and the preliminary test results of FY 2021 planned Code Case testing at ORNL.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Micromechanics of Fracture Propagation During Multistage Stress Relaxation and Creep in Brittle Rocks

Time-dependent rock deformation caused by the initiation and growth of fractures leads to the weakening of the rock mass. Understanding the fracturing mechanisms involved in the time-dependent behavior in brittle rocks is very important and to achieve this goal, a systematic series of three types of experiments was performed on double-flawed prismatic Barre granite specimens under unconfined compression. The first series aimed to identify the failure mechanism in the short-term failure mode under monotonic loading, the, second series involved multistage relaxation (constant strain) experiments to analyze the damage at different strain levels, and the third series explored the fracture propagation under multistage creep (constant load) experiments. The spatial and temporal evolution of cracking mechanisms were evaluated using the acoustic emission (AE) and two-dimensional digital image correlation (2D-DIC) techniques to observe the whole crack growth process as well as the accumulated inelastic strain at the specified region of interest. Results suggest that in the case of multistage creep experiments, the time to failure was less compared to the multistage relaxation, when loaded above the crack damage threshold (CD) estimated from the monotonic testing. Furthermore, the frequency magnitude distribution of the AE events generated in the three loading conditions followed the Gutenberg Richter model. A relatively lower b-value was obtained for the creep experiments, indicative of high energy AE events and faster crack growth. In addition, the AE and DIC results also revealed high evolution of tensile cracks at-different stages of creep and relaxation compared to shear and mixed-mode cracks.

58 GEOSCIENCES↗
DOE OSTI2014

Creep and Creep-Fatigue of Alloy 617 Weldments

Alloy 617 is the primary candidate material for the heat exchanger of a very high temperature gas cooled reactor intended to operate up to 950°C. While this alloy is currently qualified in the ASME Boiler and Pressure Vessel Code for non-nuclear construction, it is not currently allowed for use in nuclear designs. A draft Code Case to qualify Alloy 617 for nuclear pressure boundary applications was submitted in 1992, but was withdrawn prior to approval. Prior to withdrawal of the draft, comments were received indicating that there was insufficient knowledge of the creep and creep-fatigue behavior of Alloy 617 welds. In this report the results of recent experiments and analysis of the creep-rupture behavior of Alloy 617 welds prepared using the gas tungsten arc process with Alloy 617 filler wire. Low cycle fatigue and creep-fatigue properties of weldments are also discussed. The experiments cover a range of temperatures from 750 to 1000°C to support development of a new Code Case to qualify the material for elevated temperature nuclear design. Properties of the welded material are compared to results of extensive characterization of solution annealed plate base metal.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Initial Development of an Improved Creep-Fatigue Design Method that Avoids the Separate Evaluation of Creep and Fatigue Damage and Eliminates the Requirement for Stress Classification

This report describes a method for capturing the effect of strain range, temperature, hold time, and elastic follow up on the cyclic life of a material undergoing uniaxial load. Developing design correlations of this type requires methods for extrapolating experimental data as a function of hold time and follow up factor. Various extrapolation methods are developed and discussed here and recommendations are developed for the final approaches to be adopted for design use. The report also describes comparisons between the new creep-fatigue design method, described here, and current creep-fatigue design methods in the ASME Boiler and Pressure Vessel Code and associated nuclear Code Cases. These comparisons demonstrate several advantages of the new method: it is easier to execute and is less over conservative than many current approaches. This report, along with a companion on extending these results to multiaxial load and on combining load cycles, represents the accumulation of several years of work on the development of this new approach to creep-fatigue design, combining an elastic perfectly plastic analysis method with simplified model tests measuring the effect of elastic follow up on creep-fatigue cyclic life. The conclusions to this report describe a path forward to developing the required design data for high temperature advanced reactor structural materials and guiding the adoption of the new method in the ASME Boiler and Pressure Vessel Code and related standards.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Environmental creep-fatigue and weld creep cracking: a summary of design and fitness-for-service practices

This report surveys current creep-fatigue design and fitness-for-service assessment procedures, with a particular focus on environmental effects and creep-fatigue cracking near weldments. Included in this assessment are the American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section III, Division 5, the British R5 standard, the French RCC-MRx design code, the ITER Structural Design Criteria, and the API-579/ASME FFS-1 fitness-for-service rules for petrochemical components. The focus of this review is to identify gaps in the available methods that could prevent regulators from evaluating future high temperature reactor designs. The report makes recommendations, where appropriate, on actions that could be taken to fill these gaps by either providing adequate assessment procedures for creep-fatigue damage in harsh environments or by evaluating strategies vendors could use to mitigate regulatory concerns with creep-fatigue damage in high temperature reactor components.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗