TECHNICAL BASIS FOR FATIGUE CRACK GROWTH RULES IN GASEOUS HYDROGEN FOR ASME B31.12 CODE CASE 220 AND FOR REVISION OF ASME VIII-3 CODE CASE 2938-1
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San Marchi, Christopher William↗
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Class B Materials Code Case
Class B Materials Code Case to include: FY25 - High temperature design methodology, overview of ASME Section III (Division 5), Design for elevated temperature service, Goal to address current gaps, evaluation of proposed rules, allowable stress development, Class A materials (existing ASME approach), variable confidence index, data extrapolation, bounding value for SEE, and next steps.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Draft ASME Boiler and Pressure Vessel Code Cases and Technical Bases for Use of Alloy 617 for Constructions of Nuclear Component Under Section III, Division 5
The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code currently only allows five materials for use in construction of nuclear components for high temperature service. These are: 2.25Cr-1Mo and V-modified 9Cr-1Mo steels, Types 304 and 316 stainless steels and the high nickel Alloy 800H. Since 2005, the US high temperature gas-cooled reactor program has been characterizing elevated temperature mechanical properties of Alloy 617 as the leading candidate construction material for the intermediate heat exchanger. After analysis of these experimental results, along with historical data and additional results available through the Generation IV International Forum, Very High Temperature Reactor, Materials Program Management Board Materials Handbook, a draft ASME Code Case to allow nuclear construction with Alloy 617 for temperatures up to 1750°F (954°C) has been developed. This report contains the Code Case for Low Temperature Service Construction of Section III, Division 5, Subsection HB, Subpart A, Class A and Subsection HC, Subpart A, Class B components, which has been approved in Section II, Materials, and Section III, Rules for Construction of Nuclear Facility Components. Supporting technical justification for the low temperature Code Case is also included. This Code Case allows use of Alloy 617 up to 800°F (425°C). This report also contains an updated draft of a Section III, Division 5, Subsection HB, Subpart B, Class A Code Case for Alloy 617 to qualify it for use in construction of nuclear components up to 1750°F (954°C) for service life up to 100,000 hours. The draft contained in Appendix 4, subject to editorial revision and approval by the ASME Special Task Group on Alloy 617 Code Qualification, will be submitted for approval by letter ballot by the appropriate ASME Committees. The technical justification supporting the Code Case is presented in Appendix 5 of this report. This background document is part of the information package that will be submitted with the Code Case for ballot.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Summary of FY 2024 A709 Code Case testing at ANL, INL and ORNL
A collaborative research and development effort in support of the Alloy 709 Code Case qualification in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors is being carried out at Oak Ridge National Laboratory (ORNL), Idaho National Laboratory (INL), and Argonne National Laboratory (ANL). Key testing data for the Alloy 709 100,000-hr near-term Code Case submittal to ASME is expected to be completed by the end of 2024, with design parameters anticipated to be finalized in FY 2025. This report summarizes the testing results for three commercial heats of Alloy 709 conducted across three laboratories, reviews the current testing status, and outlines the remaining data needed to support the first Alloy 709 Code Case submittal to ASME. The Alloy 709 Code Case plan remains on schedule.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Interim Mechanical Properties Data from FY2022 ORNL Testing of A709 with Precipitation Treatment for ASME Code Case Data Package
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.
36 MATERIALS SCIENCE↗
Progress Report on Alloy 709 Base Metal Code Case Testing at ORNL in FY 2023
A collaborative research and development effort in support of the Alloy 709 Code Case qualification in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors is being carried out at Oak Ridge National Laboratory (ORNL), Idaho National Laboratory (INL) and Argonne National Laboratory (Argonne). In FY 2023, ORNL has continued to conduct a subset of the Code Case testing for tensile, creep rupture, fatigue and creep-fatigue on Alloy 709. This report also updates the key Code Case testing status and results on the first two commercial heats and the preliminary results on the third commercial heat of Alloy 709. The three commercial heats of Alloy 709 are all in plate product form.
36 MATERIALS SCIENCE↗
Report on FY 2023 Welding R&D at ORNL in support of ASME Alloy 709 Code Case Development
As part of the Alloy 709 (A709) ASME Code Case development effort under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of A709. This report summarizes the A709 welding research conducted at Oak Ridge National Laboratory (ORNL) in FY 2023. One of the focuses of the A709 welding research at ORNL is to relax the restriction of the P content in the A709 filler metal weld wire. In this report, we show the success in welding of high phosphorus (P) commercial A709 plates using A709 weld wires with relaxed P content of 80 wppm. A test weld was fabricated with the 80 wppm weld wire on the first commercial heat A709 base metal with 140 wppm P content using gas tungsten arc welding (GTAW). The test weld passed all weld qualification tests without issues. This study concludes that A709 matching filler metal with moderate amount of P of less than 80 wppm could be used to produce code qualified A709 welds with standard welding process without special treatment. It is recommended that the P level in the weld wire to be kept low to avoid hot cracking. Cross-weld specimens were machined from the two A709 production welds.. Cross welding creep rupture Code Case testing on these two production welds was initiated . The preliminary cross-weld creep tests results continue to show little or no creep strength reduction relative to the base metal.
36 MATERIALS SCIENCE↗
Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications
This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.
Messner, Mark C. (ORCID:0000000200404385)↗
FY20 Status Report on Creep Rupture Testing to Support the Development of Alloy 709 Code Case
This report provides an update on the status of the creep rupture testing on the first commercial heat of Alloy 709 in support of the Alloy 709 Code Case development. A creep test laboratory has been set up at ANL that comprises of 15 indirectly loaded test frames capable of testing ASTM-size specimens of the commercial heat of Alloy 709. The systems are equipped with high temperature furnaces capable of operation up to 1000°C in an air environment. During FY18, uniaxial ASTM-sized creep specimens were fabricated from 9 Alloy 709 plates that were processed by AOD, ESR, and ESR-homogenized routes and subsequently solution annealed at 1050, 1100, and 1150°C, and creep-rupture tests were performed at 330MPa and 600°C. The test results led to the down selection of the ESR-1100°C condition to support the code case. In FY19, 15 creep-rupture tests of the ESR-1100°C material, requiring the use of Type K thermocouples, were initiated to support the 100,000-hour Code Case. 8 tests were completed in FY19. In FY20, 6 tests were completed at the time of writing this report. In addition, 1 more test were loaded in FY20, using Type S thermocouples, and was completed. This report presents the data from the completed tests in FY20 and also the microstructural characterization of the fractured specimens. The creep data enabled the preliminary analysis of the creep behavior of this material. The characterization showed that in brittle fractures, the pores were narrow and thin, and elongated in the direction perpendicular to the loading direction, while in ductile fractures, the pores were much rounder. Dense precipitates were observed in all the samples, the size of which grew with test temperature. Some of the precipitates could be identified to be M23C6 based on their cuboid shape.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Complete the Planned FY24 Design Parameters Development at INL to Support the Drafting of the A709 Near-Term Code Case
This report presents the thermophysical properties measurements conducted in the Fiscal Year 2024 to extend the database up to 1000?. The new values are compared against properties of high Molybdenum steels in the ASME Section II Part D tables. This report also shows the comparison between new measurements against the previously measured values in literature and provides recommended thermophysical properties for A709 code case. These values will support the thermophysical property tables in near term code case of A709.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
A summary of the mechanical properties data developed in FY 2023 by ANL, INL and ORNL to support the data package development for the A709 Code Case
This report provides the status of tensile, creep, fatigue, and creep-fatigue testing to date conducted at Argonne National Laboratory, Idaho National Laboratory, and Oak Ridge National Laboratory to generate the data package required to qualify Alloy 709 in American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section III, Division 5. The Division 5 Class A Alloy 709 Code Case requires data generated from a minimum of three commercial heats. Extensive mechanical properties data have been generated on two commercial heats, and some initial test data have been generated from the third commercial heat. The room temperature tensile test results for the three commercial heats met the specification minimum of the American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section II, Part A, SA-213/SA-213M for Grade TP310MoCbN (UNS S31025) seamless tubing. These three commercial heats of Alloy 709 are suitable for generating the code case data.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Interim Report on FY22 ORNL A709 Welding Research and Testing of Production Welds in Support of Developing ASME A709 Code Case Data Package
As part of the Alloy 709 ASME Code Case development effort under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. This report summarizes the Alloy 709 welding research conducted at Oak Ridge National Laboratory (ORNL) in FY 2022. Two new production welds were fabricated on two commercial heats of Alloy 709 of different phosphorus (P) levels using Alloy 709 filler metal with P content less than 20 wppm with gas tungsten arc welding (GTAW). Both production welds successfully passed ASME Section IX weld qualification tests, and this concludes the Alloy 709 welding procedure development to scale up to 2-in thick plates. In FY 2022, we also demonstrated the success in welding of high P commercial Alloy 709 plates with weld wires having higher P content at 30 wppm. A test weld fabricated with the 30 wppm weld wire on the first commercial heat (140 wppm P) passed all weld qualification tests without issues. Additionally, experiment setup and testing procedure of the circular patch weldability test has been developed, for evaluating the P effect in weld wire on solidification cracking susceptibility of Alloy 709 weld, with the preliminary results summarized in this report. Research on further relaxing the P level restriction beyond 30 wppm are planned in FY 2023. The preliminary cross-weld creep tests results continue to show little or no creep strength reduction relative to the base metal.
36 MATERIALS SCIENCE↗
A709 Code Case Design Parameters
Joint ART Materials/AMMT Program Review to be given at DOE Headquarters on June 5-8, 2023. A709 Code Case Design Parameters regarding preliminary efforts have been started to develop design parameters from test data. Thus far, most of the data evaluated were from the first two commercial heats. Data from these commercial heats continue to support the creep strength advantage of A709 over 316H. Design parameters will be refined as more data are available. Work on the development of other design parameters will begin as data become available.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
FY21 Status Report on Creep Rupture Testing at ANL to Support the Development of Alloy 709 Code Case
This report provides an update on the status of the creep rupture testing on the first commercial heat of Alloy 709 in support of the Alloy 709 Code Case development. Creep tests were performed in air on the lever-arm load frames in the Mechanical and Environmental Testing Laboratory at Argonne National Laboratory (ANL). In FY21, the focus was on the age-hardened ESR-1150°C material. Twenty two tests were initiated, among which ten were completed. This report presents the data from the completed tests. Metallographic characterization of the fractured specimens were performed and the results are included. The creep data enabled the preliminary analysis of the creep behavior of this material. The characterization showed the effect of test temperature and stress on the deformation microstructure.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Application of C ( t )-Integral Solutions in Extending ASME BPVC Section XI Division 2 Code Case N-934 for Transient Creep Crack Growth
Creep crack growth is a phenomenon which arises in damaged metallic structures under combined primary and secondary loads in the creep regime. The High Temperature Flaw Evaluation Code Committee of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) is evaluating methods in extending Code Case N-934 to capture transient creep crack growth. Here, this paper provides context and basic examples on the selected approach to transient creep crack growth methods based on the C(t)-integral. The basis for selected C(t)-integral solution as analytical method is established, including an overview of its derivation. Practical assessments of a crack growing under creep conditions in a realistic component are conducted to illustrate the analytical approach. Additional considerations in the application of the analytical methods and limitations are discussed.
36 MATERIALS SCIENCE↗
FY25 Status Update on A709 Code Case Testing at ANL
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.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
ASME Code Revisions to Incorporate 316H and Alloy 617 Viscoplastic Constitutive Models to Section III, Division 5 and Code Case N-898
This report provides a final status update on work to develop and implement two new constitutive models for 316H stainless steel and the Ni-based Alloy 617 in Nonmandatory Appendix Z to the Section III, Division 5, Subsection HB, Subpart B ASME Boiler & Pressure Vessel Code rules covering the design and construction of Class A high temperature nuclear reactor components. This report summarizes the objections of the overall project and provides the final versions of the constitutive models proposed for incorporation into the ASME Code. The report also provides an update on the balloting status at ASME of the two proposed constitutive models. As of the time of writing (July 2022) the models are on-track to be approved by ASME after the August 2022 Code Week. If so, this will mean the 316H model will be published in the 2023 edition of the Code and the A617 model available as part of a revised Code Case immediately
36 MATERIALS SCIENCE↗
FY23 Status Report for A709 Code Case Creep Testing at ANL
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 American Society of Mechanical Engineers (ASME) Alloy 709 Code Case development. In Fiscal Year (FY) 23, 11 new tests were initiated and 11 tests were ruptured, some of those were initiated in FY21 or FY22. This report presents the creep data and the metallographic observations on selected rupture specimens.
36 MATERIALS SCIENCE↗