Professional Documents
Culture Documents
ISSN: 2278-0181
Vol. 3 Issue 11, November-2014
Abstract— Analysis of creep damage in steels used in the power It is commonly accepted that the voids that are created by the
generation industry is usually carried out by means of nucleation of cavities due to dislocations due to grain
traditional creep detection techniques, but the several boundary sliding, tend to align themselves perpendicularly
shortcomings of these methods have induced a search for with respect to the direction of the applied load [2,3]
alternative non-destructive testing techniques, varying from subsequently converging into microcracks and finally
ultrasonic to electromagnetic methods. During high temperature macrocracks which lead to creep damage and fatigue failures
creep there are significant changes in the microstructure such as [4,5]. Since cracks may grow and propagate very quickly,
dislocation movements and grain boundary cavities. Magnetic which may cause sudden failure of the materials, it is of great
hysteresis measurements have been used to evaluate fatigue and
importance to detect creep damage in its early stages. It is
creep damage in power plant welded joints. A critical review of
rational to assume that, in components subjected to uniformly
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the main results obtained for the different stages of creep is
presented in this paper, and the pros and cons of each method distributed mechanical loads and thermal stresses, creep and
are discussed separately. Some methods are very promising like fatigue damage will also be wide spread (throughout the
ultrasonic testing method, but the limitations are to be removed volume of the component) and multiple cracks will grow and
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with further research before they are employed on industrial propagate over a considerable large part of area of the
scale. component. [6]. Critical locations are to be monitored
regularly where failure is likely to originate. In particular,
Keywords— Creep, ultrasonic, pipeline steels, hysteresis initial failures due to localized creep in welded parts of the
component are of primary concern for the power generation
INTRODUCTION industry. Following a suggestion by [7], cracks in welded
parts are commonly classified into four types, depending on
Creep is the phenomenon of a material to deform permanently their location.
under influence of different mechanical loads. It can occur due
to the influence of high levels of mechanical and thermal
stresses that are below the yield strength of the material. Three
stages of creep are shown in the plot of strain versus time as
shown in Fig. 1. After the application of load, a sudden strain
is observed, followed by the primary stage during which the
strain rate decreases, until a steady creep rate is reached, this
secondary stage of creep, characterized by a slow but constant
plastic flow of material, usually accounts for the longest part
of the creep life of a component. Then finally it reaches the
tertiary stage, the strain increases considerably and the
component finally fails. This behavior is the cumulative result
of several mechanisms operating independent of each other. In
the ranges of temperature and stress commonly encountered in
engineering applications, the most significant causes of creep
at a micro level are the motion of dislocations and the
diffusion of vacancies [1].
The first and second type originate inside the welded part but 1.1. Wave Velocity
the third and fourth type cracks are produced at the heat Ultrasonic wave velocity calculations are dependent mainly
affected zone. Type three especially occurs at the coarse on the variations in material properties of the component such
grains areas of the material whereas type four cracks occur at as
the narrow fine grained region. The component material in density and modulus of elasticity which are indeed due to the
this area has lower creep strength [8], [9] and [10] and variations in the microstructure geometry. The
therefore represents an initiation site for the occurrence of correspondence among porosity of the material and velocities
creep cracks, which can arise as a result mechanical, thermal of the ultrasonic waves have been analyzed in previous
and residual stresses [11]. The concentration of cavities is
papers [19] and [20], but many additional factors join
usually much greater in this area and that Type four cracks are
together to cause velocities to change with their respective
the most usual causes of creep damage and fatigue failure for
ferritic steel pipes and thermal boilers in power creep life. Variations depend on material property, wave
stations [12], [13], [14], [15] and [16].In case of stainless property and also the directions of wave propagation and
steels, it is observed that cracks normally occur at the strain- polarization and of the applied stress [21]. In the initial stages
hardened areas which are close to the welded parts that have the change is small and thus it is very tough to determine the
not been undergone heat treatment for the removal of internal crack in the field [22], also because of the material defects
residual stresses [17] and [18]. and inhomogeneities that are present in the sample material
under observation [23]. It is also assumed that the estimation
TECHNICAL DIAGNOSTICS of porosity in the later stages is also possible with this
During the operation period, fatigue of steam line components technique [22] and [24]. Tests were performed on the aged
occur. Degradation of material properties and deformation of sample of Cr-Mo and the results showed that the variation in
elements are accelerated due to the exploitation and repair the velocity was increasing with the ageing time. The above
errors, therefore regular diagnosis of the materials are required result is due to the formation and broadening of the
for better maintainence. In this way, processes that could lead intermetallic precipitates [25].
to the creation of system damage are under systematic control,
what is also the legal obligation imposed by the regulations, 1.2. Birefringence
directives and harmonized standards. Properly conducted This phenomenon is purely based on the difference between
technical diagnostics protects parts of the steam line from the velocities of two longitudinal waves which are polarized
accident, and also ensures safer conditions for employees as orthogonally. As the accurate data of the two velocities are
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well as rational techno-economic exploitation and not determined, calculations of the actual velocities of the
maintenance. waves are very sensitive for the determination of creep cracks
NDT TO DETERMINE FAILURE and fatigue failures. The proposed principle states that, since
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For purpose of detection of causes of fatigue failures and microcracks are oriented with the internal cavities, along the
creep damage the steam line pipe steels should be best suited direction of main thermal stress, the changes in the velocities
for normal visual inspection, it should possess magnetic of the two waves in two orthogonal directions will vary along
property so that magnetic methods can be used, it should be with the complete creep life of that material. It has been
continuous for applying ultrasonic methods and hardness tests, observed that birefringence changes are really very tedious
it should be chemically stable so that different dye penetrant with respect to the porosity and creep life of the material [26].
tests are performed for the detection of creep cracks and the It is higher than the normal scattering of a material caused by
most important factor being the internal defects that are its material defects and calculation validity [21], [27].
produced during the manufacturing stages of the components
should be avoided because these internal defects interfere with 1.3. Wave attenuation
some NDT techniques and the data recorded are not accurate There are certain controversial conditions on the possibility
and reliable. If necessary, other tests that would give us a of using wave attenuation for the evaluation of creep and
reliable and useful results to determine causes of failure could fatigue damages. This method is not preferred over wave
be done.
velocity because small difference in grain size index (N)
would create large variations of the attenuation coefficient
[22], [28], [29]. Some however, claim that the attenuation
1. ULTRASONICS coefficient produces a greater sensitivity to creep and fatigue
Ultrasonic testing techniques have long success history in
damage than the ultrasonic wave velocity technique [24] and
many NDT use both in lab conditions and on field
[30]. In the work [30], [31] the attenuation coefficient
applications, but its use for the detection of creep in the
variation is not monotonic in nature but there are certain
primary stages has given combined results that hinders its
relationship with different creep stages. A maximum is
applications in most industries. The sensitivity, accuracy and
reached at 30–60% of creep life, depending on the material
efficiency of ultrasonic testing has considerably improved
and the temperature of application.
over the years. But, the application of ultrasonic testing at the
critical working temperatures of power plants is a major area
1.4. Backscatter
of research as most of the results from earlier data are
This advanced method is based on the study of ultrasonic
recorded at normal cryogenic temperature.
backscattering. Microstructural features such as grain
boundaries, inclusions, cavities and micro cracks create a
partial reflection of the ultrasonic wave; a frequency analysis
of the signals received between the excitation pulse and the specimens. A strong measure of agreement has been found on
arrival of the first back-wall echo is then conducted to obtain the behaviour of the remanence in Cr–Mo steels: the
information on the state of the material. The parameter most observed
commonly used is the integral of the amplitude versus decrease with creep life is due to the demagnetization caused
frequency spectrum. Material noise due to inhomogeneities by the presence of cavities in low-alloy (pearlite) steels such
can cause large errors at early stages, while coarsening of as 0.5Cr-0.5Mo-0.25V, 1.25Cr-0.5Mo and 2.25Cr-1Mo
precipitates and other microstructural changes due to thermal [36,37,39,40] and by the precipitation of non-magnetic
ageing can affect the results obtained with this method [32]. carbides in the martensitic 9Cr-1Mo steel [41]. However, the
However, a detectably greater backscatter is produced by the measurements generally present a very large scatter.
development of micro- and macro crack in the final stages of
creep life [33, 34]. 2.2. Barkhausen emission
Unlike other ultrasonic techniques, backscatter can be used A study on service-exposed 13-CrMoV-44 steel [42] reported
for the evaluation of localized creep. Destructive that the maximum value of Barkhausen emission as a
metallographic analyses of crept specimens, including function of creep life increased initially and then decreased,
weldments, confirmed in each case that the most damaged while the magnetic field at which this maximum was attained
areas were those highlighted by this method [32–34]. decreased and then increased correspondingly. This
behaviour was ascribed to the initial coarsening of grains and
1.5. Miscellaneous ultrasonic techniques precipitates followed by the formation of cavities which
Nonlinear ultrasonic and acousto-ultrasonics are emerging restrict the movement of magnetic domain walls.
techniques that have shown some promise for creep damage An opposite trend was found in a study on modified 9Cr-1Mo
assessment. Nonlinear methods such as acousto-elasticity, steel (with added Nb and V) [43], where the decrease of the
harmonics generation, non-collinear mixing, etc., are very average amplitude of the Barkhausen signal during the
sensitive to increasing dislocation density and other subtle primary stage of creep and its increase in the secondary and
lattice imperfections that might remain hidden from the above tertiary stages were attributed to the precipitation and later
discussed conventional linear ultrasonic methods. For coarsening of carbides, i.e. to the same mechanism used by
example Baby et al. [35] used second harmonics generation the same authors to explain the variations in coercivity.
to evaluate creep damage in IMI 834 titanium alloy and found Indeed, a clear relationship between coercivity and magnetic
good agreement between the measured nonlinearity Barkhausen signal has been observed on ferritic stainless
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parameter and the data obtained from metallographic studies. steel subjected to plastic deformation in tensile tests at room
temperature [44].
2. MAGNETIC METHODS 2.3. Magneto-acoustic emission
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The application of magnetic NDE techniques is obviously It was long believed that signals could also be generated by
restricted to ferromagnetic materials and to those cases where the creation or annihilation of domains [45], but evidence to
ferromagnetic phases are present within a non-ferromagnetic the contrary has recently been reported [46]. An important
material, although in the latter case the resulting wild difference with the Barkhausen emission technique is that
variations in permeability with position render the inspection MAE signals can be detected from the bulk of the material,
particularly difficult. the maximum measurement depth being determined by the
2.1. Magnetic properties penetration of the excitation field. It should be observed that
Inspection methods based on variations in magnetic the results of both MAE and Barkhausen emission are not
properties have attracted the attention of many researchers. repeatable because it is not possible to bring the magnetic
While these techniques have sometimes been hailed as more domains back to exactly the same state as before the
promising than those based on ultrasound, doubts persist on inspection.
their selectivity, since factors including cold work, localized 3. HARDNESS
differences in the composition of the alloy, and the presence Measurements of Vickers hardness have been considered
of residual stresses can cause changes in magnetic properties in many studies on creep damage, usually in addition to other
[36, 37] to a larger extent than they affect the propagation of techniques. The microstructural changes associated with
ultrasonic waves. thermal aging or creep have a different effect on different
In a study on austenitic stainless steel 304, it was observed materials: on Cr–Mo steels an approximately linear decrease
that magnetic phases formed at grain boundaries in a in hardness was observed between 20% and 90% of creep
specimen life, followed by a dramatic drop at rupture, as shown in Fig.
subjected to thermal aging at 650 1C, and also in grains 9 [33, 47, 48-50], whereas in austenitic steels hardness was
themselves in a specimen crept to rupture at the same found to increase, especially in the second half of creep life
temperature. Since these magnetic phases can be found at an [51, 52]. In almost all cases, thermal aging in the absence of
early stage, changes in the magnetic properties may be used mechanical loads was found to have similar but less
to pronounced effects. In creep tests on Cr–Mo steels it has been
detect creep damage before cavities or microcracks start observed that hardness starts decreasing at smaller values of
developing [38]. In ferritic or martensitic steels, however, the Larson–Miller parameter for loads higher than about 100
these small changes would be hidden by the strong point-to- MPa [53–55] and that the value of Vickers hardness at
point permeability variations observed even from intact rupture is lower for those specimens tested at lower stress
levels [56].
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There are instances where potential drop technique is Analysis, 4 (2) (1997), pp. 89–98.
certainly able to detect creep damage at primary stages as [13] J. Budden, International Journal of Pressure Vessels and Piping, 75
(1998), pp. 509–519.
compared to other NDT conventional methods who fail
[14] F. Ellis, R. Viswanathan, Fitness for service evaluation in petroleum
to do so. and fossil plants ASME, New York (1998) pp. 59—76.
The overall results of this review work recommends that [15] J.A. Francis, W. Mazur, H.K.D.H. Bhadeshia, Materials Science and
much more research is required in this field and the most Technology, 22 (12) (2006), pp. 1387–1395.
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[17] M.C. Coleman, D.A. Miller, R.A. Stevens, Proceedings of the
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employed in various stages according to the various variables [23] Saniie J, Panda B, Wang T, Nagle DT. In: Proceedings of the 1990
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[26] Morishita T, Hirao M, Fukuoka H. Journal of the Society of Materials
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