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The goal of the project is to reproduce the rupture lifetime data for nuclear steel (here, 316H) via onset of tertiary creep, create a predictor tool for other similar materials.
This presentation at ICAM 2024 Conference focuses on the commonalities and differences in the creep rupture behavior and creep mechanisms for three distinct classes of laser powder-bed fusion (L-PBF) Ni-based superalloys (γ’-precipitate strengthened Haynes® 282®, γ’/γ”/δ-precipitate strengthened Alloy 718, and solid-solution strengthened Alloy 625) as compared to conventionally processed counterparts. A comparison of Larson-Miller parameter plots establishes that these alloys perform statistically within the bounds established for the wrought product, despite having dissimilar microstructural features and other artefacts associated with PBF-LB manufacturing and post-processing heat treatment. To understand the failure and the impact of composition, minor phases, and deformation defects on creep behavior, the fractography has been performed and microstructures have been evaluated in detail with SEM-EDS, EBSD, and HAADF-STEM. The underlying diffusional and dislocation creep mechanisms associated with this microstructural evaluation is discussed. This work is supported by NETL-FWP-1022408 Advanced Turbines.
Limited studies have evaluated the creep behavior of additively manufactured (AM) ferritic-martensitic (FM) steels. This work investigated the creep behavior of a 9Cr FM steel fabricated by powder blown directed energy deposition (DED) technique. Here, the creep testing at 550–650 °C and 150 MPa for the specimens along the deposition direction in the as-built condition, together with corresponding microstructural characterization, revealed a threshold temperature between 600 and 625 °C, below which the steel has creep resistance comparable with Grade 91 cross-welds and noticeably greater than 9Cr-1Mo steel. The threshold temperature distinguishes the creep behavior in two regimes differentiated in creep activation energy, creep deformation, and failure mechanism. Unlike the creep rupture surface ~45° from the loading direction when tested above the threshold temperature, the creep rupture for testing below the threshold temperature resembles type IV failure in the cross-welds of ferritic steels. The DED-induced layer structure in the as-built steel played a significant role on the change of creep behavior.
This report summarizes the progress made on the project during the first quarter of FY22. The model for deep penetration laser welding continues to be developed to understand and mitigate cracking issues associated with laser welding Alloy 740H. The effects of laser wobble on laser welding of this alloy are also being developed. Additionally, the short-term creep behavior of welds made by various hybrid laser arc parameters has been obtained and the results indicate they are comparable to welds made by conventional gas tungsten arc welding which is a factor 2 slower than the hybrid welds. Additionally, the creep behavior of laser-only welds is also consistent with conventional gas tungsten arc welds as well as the hybrid laser arc welds made under this project. However, the creep rate of the laser-only welds is much higher than that observed in the hybrid laser arc welded specimens. This is most likely due to the narrower weld produced by laser-only welding compared to hybrid laser arc welding and, thus, the higher creep rate of laser-only welded creep specimens is likely a result of the increased fraction of base metal (which exhibits a higher creep rate than weld metal) contained within the gage section of the creep specimen. Creep rupture lifetimes were all about the same for both laser-only and hybrid laser arc welded specimens and consistent with the creep rupture lifetime of conventional gas tungsten arc welded creep specimens.
Here, this paper presents the results of a comprehensive effort to characterize the properties of Inconel 718 produced by a form of laser powder bed fusion (LPBF) additive manufacturing (AM) or 3D-printing, subsequently subjected to hot isostatic pressing (HIP) and heat treatment according to standards F3055-14a and AMS 5663, respectively. Material property data, while broadly available for traditional Inconel 718 presentations (e.g. forgings or castings), is currently lacking for the 3D-printed material. It is expected that while limited in size, the experimental data sets presented provide sufficient information to glean the capability of LPBF Inconel 718. These include: 1) Chemical composition, electron backscatter diffraction (EBSD), and x-ray energy dispersive spectroscopy (XEDS) characterization of 3D-printed material structure; 2) Tensile properties — 0.2% yield stress, ultimate stress, modulus of elasticity, and elongation to failure — based on 108 samples, as functions of temperature and sample print orientation; 3) Creep rupture data including the Larson-Miller parameter, based on 21 samples; and 4) High cycle fatigue data based on 21 samples as a function of temperature. Results are compared to available standards and/or data for forged, cast, and other AM Inconel 718. A key observation of this study, based on the EBSD results, is that while the material appears to approach full recrystallization following heat treatment, there is a detectable fraction of the material that does not fully recrystallize, resulting in a material with mechanical properties (e.g. yield stress, creep rupture) measurably lower than those of forgings, but higher than those of castings.
A709 was selected to be qualified in Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code. Idaho National Laboratory (INL), Argonne National Laboratory and Oak Ridge National Laboratory are collaborating to develop and qualify A709 plate. Aging A709 to form beneficial precipitates prior to service is investigated. One tensile test, five creep-rupture tests, and eight cyclic tests have been completed on aged A709. Two creep-rupture tests are in progress.
The Larson-Miller parameter (LMP) offers an efficient and fast scheme to estimate the creep rupture life of alloy materials for high temperature applications. However, owing to poor generalizability and dependence on the constant C, which is typically not known a-priori, estimations using the Larson-Miller parameter often result in suboptimal performance for a wide range of materials. At best it is useful in comparing alloys of similar composition. In this work, three machine learning (ML) schemes were developed for rupture life prediction for 9-12% Cr ferritic-martensitic steels and austenitic stainless steels, i.e., a hierarchical model to parameterize LMP using the LMP constant C to compute rupture life, a hierarchical model to parameterize both C and LMP to compute rupture life, and a direct prediction of rupture life. Specifically, we show that the third scheme, using a gradient boosting algorithm, can be used to train ML models for very accurate prediction of rupture life in a variety of alloys (Pear-son Correlation Coefficient > 0.9 for 9-12% Cr and > 0.8 for austenitic stainless steels). In addition, the Shapley value was used to quantify feature importance, making the model interpretable by identifying the effect of various features on the model performance. Furthermore, a variational autoencoder-based generative model was built by conditioning on the experimental dataset to sample hypothetical synthetic candidate alloys from the learnt joint distribution not existing in both 9-12 % Cr ferritic-martensitic steel and austenitic stainless steel datasets. Finally, based on the predictive and generative model, a reinforcement learning strategy has been proposed to guide experimentalists into designing better heat resistant alloys.
An alloy includes in weight % based upon the total weight of the alloy: 28-35% Cr; 2.5-4% Al; 0.8-2% Nb; 5.5-7.5% W; 0-0.5% Mo; 0-0.3% Ti; 0.1-0.3% Zr; 0.1-1% Si; 0-0.07% Y; 0-2% Mn; 0-1% Ni; 0-0.05% C; 0-0.015% B; 0-0.02% N; 0.02-0.04 Ce; balance Fe. The alloy includes a recrystallized, equi-axed grain structure, and forms an external alumina scale, and has strengthening particles including Fe2M (M: Nb, W, Mo, and Ti) type C14 Laves-phase, and a BCC ferritic matrix microstructure from room temperature to melting point with less than 1% FCC-phase, less than 1% martensite phase, less than 0.5 wt. % of carbides (MC and M23C6), and at least 1% tensile elongation at room temperature. The alloy provides a creep resistance of greater than 3000 to 15000 h creep rupture life at 750° C. and 50 MPa, or greater than 500 to 5000 h creep rupture life at 700° C. and 100 MPa.
There is a critical lack of data on the mechanical behavior of candidate structural materials for advanced nuclear reactors under molten halide salt environments. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy in molten fluoride salt. With ongoing efforts to commercialize different molten salt reactor concepts, the industry can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. The present work aims to assess the role of molten salt corrosion on the creep behavior of three alloys 316H, 617 and 282 at 650-816 °C. Creep tests were conducted in fluoride (FLiNaK) and chloride (NaCl-MgCl2) salts. Initial results from the ongoing testing will be presented which suggest that the molten salt environment caused a 25-50% reduction in creep rupture lifetime compared to air exposures. Physics-based corrosion and creep models were employed to gain some insights into the potential degradation mechanisms.
The mechanical behavior of a cast form of an advanced austenitic stainless steel, CF8C-Plus, is compared with that of its wrought equivalent in terms of both tensile and creep-rupture properties and estimated allowable stress values for pressurized service at temperatures up to about 850°C. A traditional Larson-Miller parametric model is used to analyze the creep-rupture data and to predict long-term lifetimes for comparison of the two alloy types. The cast CF8C-Plus exhibited lower yield and tensile strengths, but higher creep strength compared to its wrought counterpart. Two welding methods, shielded-metal-arc welding (SMAW) and gas-metal-arc welding, met the weld qualification acceptance criteria in ASME BPVC Section IX for the cast CF8C-Plus. However, for the wrought CF8C-Plus, while SMAW and gas-tungsten-arc welding passed the tensile acceptance criteria, they failed the side bend tests due to lack of fusion or weld metal discontinuities.
A compositional modification has been proposed to validate an alloy design which potentially eliminates the requirement of post-weld heat treatment (PWHT) while preserving the advantage of mechanical properties in a reduced activation bainitic ferritic steel based on Fe-3Cr-3W-0.2V- 0.1Ta-Mn-Si-C, in weight percent, developed at Oak Ridge National Laboratory in 2007. The alloy design includes reducing the hardness in the as-welded condition for improving toughness, while increasing the hardenability for preserving the high-temperature mechanical performance such as creep-rupture resistance in the original steel. To achieve such a design, a composition range with a reduced C content combining with an increased Mn content has been proposed and investigated. Newly proposed “modified” steel successfully achieved an improved impact toughness in the as- welded condition, while the creep-rupture performance across the weldments without PWHT demonstrated ~50% improvement of the creep strength compared to that of the original steel weldment after PWHT. The obtained results strongly support the validity of the proposed alloy design.
This report provides an update on the status of the creep rupture testing on the precipitation-treated (PT) Alloy 709 samples fabricated from the first, the second and the third commercial heats, in support of the first, 100,000-hour Alloy 709 Code Case development under the American Society of Mechanical Engineers (ASME) Section III, Division 5 for high-temperature reactor construction. In Fiscal Year (FY) 25, no new tests were initiated, while 5 previously loaded tests were completed. This report presents an overview of the creep-rupture data gathered at Argonne National Laboratory (ANL) since FY21 that totaled 52 completed tests. Metallographic images showing crack morphologies in some representative samples ruptured in FY25 are also included. Key conclusions include: 1) the creep behavior of the three heats of Alloy 709 can be well described by the Larson-Miller relationship; 2) higher temperatures and larger stresses lead to shorter creep life and higher minimum creep rate; 3) Alloy 709 is overall very ductile under creep; 4) the crack morphologies near fracture surfaces are dependent on material’s grain size and test conditions.
For the advancement and development of nuclear systems used in heavy irradiation environments such as fusion DEMO reactors, fission reactors, fast reactors, and accelerator driven target systems, it is necessary to fully understand the changes of mechanical properties and the other properties of the materials induced by irradiation and to clarify the synergistic effect of displacement damage and helium generation. In this study the mechanical property changes and microstructural development induce by displacement damage and helium production have been mainly examined in austenitic stainless steels, 316FR and type304, and ferritic/martensitic steel, HCM12A, irradiated at around 550oC in JRR-3M reactor and/or JOYO fast reactor. At 550°C, 316FR steel was superior to 304 steel in terms of the amount of ductility and strength with respect to irradiation resistance. It is noteworthy that at 550 °C as well as room temperature, the higher fracture strength of the 316FR steels is a remarkable result. It is found that helium atoms strongly influenced on creep lifetime of the irradiated austenitic stainless steel, 316FR. It was found that the ratio of creep rupture time is slightly lower than the lower limit of previous study’s Miyaji and co-workers in the region from 0.01 appm to 1 appm. It is also found that the lower limit of reduction ratio of creep rupture time (irradiation specimen to unirradiation one) does not decrease linearly with the helium production above 10 appm up to about 33 appm. dpa enhanced the reduction of creep lifetime. Recent R&D of high-energy accelerator driven target systems used under heavy irradiation environment is also introduced and discussed for high radiation resistance materials such as Ti alloys with very high number density of nano size precipitate, which have been studying under RaDIATE collaboration, from points of view of irradiation damage and materials development.
Abstract The class of 9–12% Cr ferritic-martensitic alloys (FMA) and austenitic stainless steels have received considerable attention due to their numerous applications in high temperature power generation industries. To design high strength steels with prolonged service life requires a thorough understanding of the long-term properties, e.g., creep rupture strength, rupture life, etc., as a function of the chemical composition and processing parameters that govern the microstructural characteristics. In this article, the creep rupture strength of both 9–12% Cr FMA and austenitic stainless steel has been parameterized using curated experimental datasets with a gradient boosting machine. The trained model has been cross validated against unseen test data and achieved high predictive performance in terms of correlation coefficient ( $$R^{2} > 0.98 $$ R 2 > 0.98 for 9–12% Cr FMA and $$R^{2} > 0.95 $$ R 2 > 0.95 for austenitic stainless steel) thus bypassing the need for additional comprehensive tensile test campaigns or physical theoretical calculations. Furthermore, the feature importance has been computed using the Shapley value analysis to understand the complex interplay of different features.
Due to the excellent long-term high-temperature performance of Alloy 617, the Alloy has been identified as the primary structural material for the intermediate heat exchanger of the Very High Temperature Reactor (VHTR). Both the base and welded alloy has been qualified to be used up to 950 °C up to 100,000 hours by the American Society of Mechanical Engineer (ASME) Boiler and Pressure Vessel Code (BPVC). The qualification properties of the material were exclusively determined by uniaxial creep tests. The components may, however, experience multiaxial stress conditions in service due to the reactor geometry. This study used notched creep tests to investigate the effect of geometric discontinuities on creep behavior of both the base and welded Alloy 617. The V-notch tests reveal that the geometric discontinuities do not reduce the creep rupture live under high and intermediate stress conditions. The U-notch tests show that a larger radius notch behave in a similar way as a straight gauge section of a uniaxial test. The creep rupture live of the welded alloy was slightly longer than the base metal.
Creep-rupture properties and oxidation behavior of a series of alumina-forming austenitic (AFA) alloys with variations of Cr contents, based on Fe-(13.5-18)Cr-25Ni-4Al-1.5Nb-0.1C in weight percent, have been evaluated at 850–900 °C. The study investigates material responses in the properties and microstructure through compositional modifications in AFA alloys, targeting performance optimization of alloys under high-temperature, corrosive industrial environments. The creep-rupture life of the alloys at 850 °C and 30MPa monotonically decreased with increasing Cr content, which was correlated with changes in secondary phase volume fractions, such as the reduction in B2-NiAl + Laves-Fe2Nb and increase in Sigma-FeCr with Cr content. The oxidation test at 900 °C in a water-vapor containing environment revealed a range of Cr content from 13.9 to 15.7 wt.%, enabling the formation of stable, protective external alumina scale as well as preventing internal oxidation/nitridation for up to total 7000 h exposure. On the other hand, the alloys with >16.7 wt.% Cr formed Sigma precipitates, which caused a reduction in not only Cr but also Al in the austenite matrix, resulting in less oxidation resistance than other alloys. The findings will guide the further optimization of material performance in the AFA alloy series.
This report provides the time-dependent allowable stress calculation strategy leveraging the limited creep rupture tests data generated to support the allowable stress for 100,000 hours in American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section II, Part D. A variable confidence index procedure to extrapolate material properties to support 500,000 hours design life is discussed. Time-dependent allowable stresses for Class B component design and analysis are presented for Grade 1 and Grade 2 of Alloy 625. The presented data extrapolation and allowable stress calculation method will support new material addition using limited creep rupture data in the new ASME Boiler and BPVC, Section III, Division 5, Class B rules.
A collaborative research and development effort in support of the Alloy 709 Code Case qualification in the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors is being conducted at the US Department of Energy’s Oak Ridge National Laboratory, Idaho National Laboratory, and Argonne National Laboratory. A recent assessment on the Alloy 709 development and testing effort concluded that the mechanical properties of Alloy 709 with the precipitation treatment continued to outperform those of Type 316 stainless steel. The assessment also affirmed the recommendation for its Code qualification. This report provides the detailed integrated data generated to date on the two commercial heats of Alloy 709 in plate product form with precipitation treatment condition that were used as the basis for this assessment. Oak Ridge National Laboratory has continued to perform a subset of the Code Case testing for tensile properties, creep rupture, fatigue, and creep-fatigue. This report also updates the key Alloy 709 Code Case testing status and results in FY 2022 at Oak Ridge National Laboratory.