Probabilistic Minimum-Creep-Strain-Rate and Stress-Rupture Prediction for the Long-Term Assessment of IGT Components

2020 ◽  
Author(s):  
Md Abir Hossain ◽  
Calvin M. Stewart
Keyword(s):  
Strain Rate ◽  
Creep Strain ◽  
Probabilistic Model ◽  
Stress Rupture ◽  
Service Condition ◽  
Creep Strain Rate ◽  
Experimental Uncertainty ◽  
Initial Damage ◽  
Long Duration

Abstract Time-dependent creep induced failure is a major concern for structural components (i.e. IGT components, Gen IV nuclear reactor components) operating at elevated temperature. The likelihood of a failure is aggravated by randomness in several sources of uncertainty. Creep rupture data shows expanding scatter bands for long-duration creep tests where uncertainty can span multiple logarithmic decades of life. This experimental uncertainty is exacerbated by the uncertainties that exist during service. The continuum damage mechanics (CDM) based creep-damage model readily available in literature does not consider the uncertainty effect while predicting the long-term reliability of the components; rather the problem is tackled deterministically. Introduction of probabilistic phenomena into the existing model to predict the minimum-creep-strain-rate (MCSR) and stress-rupture (SR) would present a pathway for estimation of effect of uncertainty ensuing high reliability in the assessment. The objective of this paper is to develop a probabilistic model for MCSR and SR that is capable of predicting experimental uncertainty and extrapolating the expanded scatter bands observed in long-duration creep data. The Sine-hyperbolic (Sinh) CDM model is selected. Multi-isotherm MCSR and SR data for 304 (18Cr-8Ni) and 316 (18Cr-12Ni-Mo) stainless steel are gathered from the NIMS material database. A deterministic calibration is performed where the optimal material constants are obtained with no initial damage and perfect loading conditions. Probabilistic calibration begins with adding ASTM-specified temperature and stress tolerances (± X°C, ±Y% MPa) to capture a portion of the experimental uncertainty. The initial damage tolerances is then calibrated to capture the remaining uncertainty in the data. Probability distribution functions (pdfs) are assigned to each uncertainty parameter. Monte Carlo simulations are performed over a range of stress and temperature. The probabilistic Sinh model is shown to predict the expanding scatter band observed in long-term MCSR and SR data. Parametric simulations are performed where service condition uncertainty is added to the probabilistic model. It is determined that service condition uncertainties further degrade the creep resistance of a material.

Application of the Wilshire Stress-Rupture and Minimum-Creep-Strain-Rate Prediction Models for Alloy P91 in Tube, Plate and Pipe Form

2019 ◽  
Author(s):  
Jaime A. Cano ◽  
Calvin M. Stewart
Keyword(s):  
Strain Rate ◽  
Creep Strain ◽  
Stress Rupture ◽  
Creep Strain Rate ◽  
Tube Plate ◽  
Short Term ◽  
Design Life ◽  
Term Creep ◽  
Term Data

Abstract There exists a challenge in predicting the long-term creep of materials (3 105 hours) where 11+ years of continuous testing is required to physically collect creep data. As an alternative to physical testing, constitutive models are calibrated to short-term data (< 104 hours) and employed to extrapolate the long-term creep behavior. The Wilshire model was introduced to predict the stress-rupture and minimum-creep-strain-rate behavior of materials and the model is well-accepted due to the explicit description of stress- and temperature-dependence allowing predictions across isotherms and stress levels. There is an ongoing effort to determine how alloy form affects the long-term creep predictions of the Wilshire model. In this study, stress-rupture and minimum-creep-strain-rate predictions are generated for alloy P91 in tube, plate, and pipe form. Data is gathered from the National Institute of Materials Science (NIMS) material database for alloy P91 at multiple isotherms. Following the establish calibration method for the Wilshire model, post-audit validation is performed using short-term data from NIMS to vet the extrapolations accuracy of each form at different isotherms. The Wilshire model demonstrates successful extrapolative techniques for the stress-rupture and minimum-creep-strain-rate of tube, plate, and pipe forms across multiple isotherms. Overall the form with the highest extrapolative accuracy for both stress-rupture and minimum-creep-strain-rate is the plate and the lowest one is the pipe. Stress-rupture design maps are provided where stress and temperature are axes and rupture-time is in contour. The design maps can be applied to: (a) given the boundary conditions, determine the design life (b) given the design life, determine the acceptable range of a boundary conditions. The latter is more useful in turbomachinery design.

scholarly journals Accelerated Creep Test (ACT) Qualification of Creep-Resistance Using the WCS Constitutive Model and Stepped Isostress Method (SSM)

2021 ◽  
Author(s):  
Jaime A. Cano ◽  
Calvin M. Stewart
Keyword(s):  
Constitutive Model ◽  
Strain Rate ◽  
Creep Strain ◽  
Creep Deformation ◽  
Inconel 718 ◽  
Creep Resistance ◽  
Stress Rupture ◽  
Creep Testing ◽  
Accelerated Creep

Abstract In this study, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire-Cano-Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing (CCT) is a long-term continuous process, in fact, the ASME B&PV III requires that 10,000+ hours of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle (TTSSP) that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The stepped isostress method (SSM) has been developed which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750°C and predictions are compared to CCT data. The WCS model has proven to make long-term predictions for stress-rupture, minimum-creep-strain-rate (MCSR), creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are post-audit validated using the National Institute of Material Science (NIMS) database. Similarly, the MCSR predictions are compared from previous studies. Finally the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and Industrial Gas Turbines (IGT).

Reliability Prediction of 304 Stainless Steel Using Sine-Hyperbolic Creep-Damage Model With Monte Carlo Simulation Method

2019 ◽  
Author(s):  
Md Abir Hossain ◽  
Calvin Maurice Stewart
Keyword(s):  
Stainless Steel ◽  
Monte Carlo ◽  
Strain Rate ◽  
Creep Strain ◽  
Creep Deformation ◽  
Stress Rupture ◽  
Material Constant ◽  
Creep Strain Rate ◽  
304 Stainless Steel ◽  
Material Constants

Abstract Typically continuum damage mechanics (CDM) based constitutive models are applied deterministically where the uncertainty of experiments is not considered. This is also true for the Sine-hyperbolic (Sinh) CDM-based constitutive model where the model is calibrated to represent 50% reliability of creep data. There is a need to implement Sinh in a more stochastic manner. The objectives of this study is to incorporate the probabilistic feature in the Sinh creep damage model to reliably predict the minimum-creep-strain-rate, creep-rupture and creep deformation. This will be achieved using Monte-Carlo methods. Creep deformation data for 304 Stainless Steel is collected from literature consisting of tests conducted at 300 and 320 MPa at 600°C with five replicates. The replicate tests exhibited substantial scatter in the minimum-creep-strain-rate, stress-rupture, and overall creep deformation. Subsequently, upon calibration using the Sinh model, the material constants among the replicates varied. The trends of uncertainty carried by each material constant are studied. The interdependence of the material constants is evaluated to determine if the uncertainty carried by each material constant can be regressed using a co-dependence function. The Monte Carlo method was applied to determine the extent that the creep deformation curve varies taking into consideration the variability of the material constants. Monte Carlo simulations show that the predicted creep deformation persists within the bounds of the experimental data. A large number of Monte Carlo simulations using the Sinh model enabled the creation of credible reliability bands for the minimum-creep-strain-rate, stress-rupture, and creep deformation of 304 Stainless Steel. In future work, this statistical method will be applied to the variability of service conditions, pre-existing defects, and material constants to quantitatively establish the reliability of the Sinh model in simulating component-level creep deformation to rupture.

Effects of ternary additions on the deformation behavior of single crystals of MoSi2

2000 ◽  
Vol 646 ◽  
Author(s):  
Haruyuki Inui ◽  
Koji Ishikawa ◽  
Masaharu Yamaguchi
Keyword(s):  
Yield Strength ◽  
Strain Rate ◽  
Single Crystals ◽  
Creep Strain ◽  
High Temperatures ◽  
Low Temperatures ◽  
Deformation Behavior ◽  
Creep Strain Rate ◽  
Compression Creep ◽  
Ternary Additions

ABSTRACTEffects of ternary additions on the deformation behavior of single crystals of MoSi2 with the hard [001] and soft [0 15 1] orientations have been investigated in compression and compression creep. The alloying elements studied include V, Cr, Nb and Al that form a C40 disilicide with Si and W and Re that form a C11b disilicide with Si. The addition of Al is found to decrease the yield strength of MoSi2 at all temperatures while the additions of V, Cr and Nb are found to decrease the yield strength at low temperatures and to increase the yield strength at high temperatures. In contrast, the additions of W and Re are found to increase the yield strength at all temperatures. The creep strain rate for the [001] orientation is significantly lower than that for the [0 15 1] orientation. The creep strain rate for both orientations is significantly improved by alloying with ternary elements such as Re and Nb.

scholarly journals Creep Strain and Permeability Evolution in Cracked Granite Subjected to Triaxial Stress and Reactive Flow

Geofluids ◽  
2018 ◽  
Vol 2018 ◽  
pp. 1-10
Author(s):  
Fan Zhang ◽  
Jianjian Zhao ◽  
Dawei Hu ◽  
Qian Sheng ◽  
Jianfu Shao
Keyword(s):  
Acid Solution ◽  
Strain Rate ◽  
Creep Strain ◽  
Alkaline Solution ◽  
Confining Pressure ◽  
Creep Strain Rate ◽  
Reactive Flow ◽  
Secondary Creep ◽  
Creep Tests ◽  
Creep Stage

Fluid flow and fluid-rock interaction mainly take place in fracture network, consequently resulting in deformation and permeability variation of rock and deterioration of the wellbore performance. Mechanical-reactive flow coupling creep tests are performed on cracked granite under various confining pressures and acid and alkaline solution flows. The testing results show that the confining pressure and solution pH significantly influence the creep deformation, creep strain rate, and permeability. A primary creep stage and secondary creep stage are observed in all creep tests in this study; notably, the sample under a confining pressure of 10 MPa and acid solution injection undergoes creep failure for over 2700 hours. The acid solution has a more obvious influence on the creep behavior than that of the alkaline solution. With an increase in confining pressure, the total creep strain and creep strain rate in the samples gradually decrease during the injection of either solution. The permeability of the samples injected with either solution gradually deceases during the testing process, and this deceasing rate increases with the confining pressure. The scanning electron microscopy observations on the crack surfaces after the creep tests show that the surfaces of the fractures injected with the acid solution are smooth due to the dissolution of the matrix, while those injected with the alkaline solution include voids due to the dissolution of quartz. These experimental results could improve the understanding of the long-term transport and mechanical behaviors of wellbore.

Creep Strength Evaluation of a New and a Used Grade 91 Welded Joints by Using a Miniature Specimen

2018 ◽  
Author(s):  
Takashi Ogata
Keyword(s):  
Weld Metal ◽  
Strain Rate ◽  
Creep Strain ◽  
Base Metal ◽  
Welded Joints ◽  
Welded Joint ◽  
Creep Damage ◽  
Creep Strain Rate ◽  
Standard Size ◽  
Grade 91

Grade 91 is widely used for steam pipes and tubes in high temperature boilers of ultra-super critical power plants in Japan. It was reported that creep damage may initiate at the fine grain region within the heat affected zone (HAZ) in welded joints prior to the base metal, so called “Type IV” damage, which causes steam leakage in existing power plants. Therefore, development of creep damage assessment methods is not only an important but also an urgent subject to maintain operation reliability. In order to evaluate creep damage of welded joints based on finite element analyses, creep deformation properties of a base metal, a weld metal and a HAZ have to be obtained from creep tests. However, it is difficult to cut a standard size creep specimen from the HAZ region. Only a miniature size specimen is available from the narrow HAZ region. Therefore, development of creep testing and evaluation technique for miniature size specimens is highly expected. In this study, a miniature tensile type solid bar specimen with 1mm diameter was machined from a base metal, a weld metal and a HAZ of a new and a used Grade 91 welded joints, and creep tests of these miniature specimens were conducted by using a special developed creep testing machine. It was found that creep deformation property is almost identical between the base metal and weld metal, and creep strain rate of the HAZ is much faster than that of these metals in the new welded joint. Relationships between stress and creep strain rates of the base metal and the HAZ in the used welded joint are within scatter bands of those in the new material. On the other hand, creep strain rate of the weld metal in the used welded joint became much faster than that in the new one. Then both the standard size and the miniature size cross weld specimens were machined from the new and the used welded joints and were tested under the same temperature and stress conditions. Rupture time of the miniature cross weld specimen is much shorter than that of the standard size cross weld specimen. The finite element creep analysis of the specimens indicates that higher triaxiality stress yields within the HAZ of the standard size specimen than that of the miniature specimen causing faster creep strain rate in the HAZ of the miniature cross weld specimen.

INDENTATION SIZE EFFECT ON THE CREEP BEHAVIOR OF A SnAgCu SOLDER

2010 ◽  
Vol 24 (01n02) ◽  
pp. 267-275 ◽  
Author(s):  
Y. D. HAN ◽  
H. Y. JING ◽  
S. M. L. NAI ◽  
L. Y. XU ◽  
C. M. TAN ◽  
...  
Keyword(s):  
Creep Rate ◽  
Strain Rate ◽  
Creep Strain ◽  
Creep Behavior ◽  
Maximum Load ◽  
Creep Strain Rate ◽  
Lead Free ◽  
Lead Free Solder ◽  
Snagcu Solder ◽  
Free Solder

In the present study, nanoindentation studies of the 95.8 Sn -3.5 Ag -0.7 Cu lead-free solder were conducted over a range of maximum loads from 20 mN to 100 mN, under a constant ramp rate of 0.05 s-1. The indentation scale dependence of creep behavior was investigated. The results revealed that the creep rate, creep strain rate and indentation stress are all dependent on the indentation depth. As the maximum load increased, an increasing trend in the creep rate was observed, while a decreasing trend in creep strain rate and indentation stress were observed. On the contrary, for the case of stress exponent value, no trend was observed and the values were found to range from 6.16 to 7.38. Furthermore, the experimental results also showed that the creep mechanism of the lead-free solder is dominated by dislocation climb.

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