MATERIAL SELECTION

Dr N S More
(Reactor Component Group)

Nuclear Power Corporation of India, Mumbai

Indo-Swiss Joint Research Fellow
(EPFL, Lausanne, Switzerland)
E-Mail: nshirish@npcil.co.in,
Cell: 9423289381

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 Introduction
 Classification Of Materials & Material Selection
Criteria
 Mechanical Properties And Testings.
 Types Of Pipes and Degradation Mechanisms.
 High Temperature Piping Material Specification.
 Guidelines For SS Pipings.
 Fiber Reinforced Plastic (FRP) Piping
 Conclusions

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1. Material selection is one of the most important steps in the
design of the engineering components.
2. Functional Requirements and operating conditions (Stress,
temperature & environment) dictate the choice of materials
and the requirement of properties.
3. Assurance of Structural integrity requires three inputs viz.
a. Stress (applied as well as residual).
b. Flaw characteristics (Type, location, size, shape &
orientation) .
c. Material Properties (Strength and toughness).
Deficiencies in material properties and processing can lead
to premature failures.
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1.1 CLASSIFICATION OF ENGINEERING MATERIALS
Engineering Materials are classified as following five groups.
I Metals & Alloys
II Ceramics & Glasses
III Polymers
IV Composites
V Semiconductors

Metals and alloys can be utilized for designing of load bearing

components. Metals and alloys are most commonly used for
designing piping. They exhibit certain unique characteristics
viz. High thermal and electrical conductivity, Malleability,
high strength and toughness.

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1.2 Classification of Metallic Materials
Metallic Materials are classified as follows:
FERROUS NON- FERROUS
METALS & ALLOYS METALS & ALLOYS

STEELS CAST IRON e.g. Cu, Al. Ni

(C>2%) (C<2%) BRASS (Cu-Zn)
DURALUMIN(Al-Cu)
MONEL (Ni-Cu)
PLAIN CARBIN STEEL
LOW MEDIUM HIGH
CARBON CARBON CARBON
STEEL STEEL STEEL
C<0.3% 0.3-0.6% >0.6%

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ALLOY STEEL
LOW ALLOY MEDIUM HIGH ALLOYING
<5% 5-10% >10%
ELEMENT

Nonferrous Metals & Alloys

Light Alloys Heavy Alloys

* Al, Mg, Ti, Be * Cu, Zn, Ni, Sn Pb

* Al alloys: High Conductivity, High Strength, Low

Density, Al alloy is having high strength to weight ratio.

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1. Ti alloys: High strength to weight ratio – Space vehicles

High corrosion resistance against sea water-Marine

applications.
e.g. Ti-6 Al-4Cu

2. Cu alloys: High Electrical & Thermal Conductivity, High

Corrosion Resistance
e.g. Brasses & Bronzes
(Cu-Zn) (Cu-Sn)

3. Ni alloys : High Oxidation Resistance & High Temp. Strength

Monel Inconel Incoloy

(Ni-Cu) (Ni-Cr-Fe) (Fe-Ni-Cr)

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1.3 STAINLESS STEEL

What is Stainless Steel?

•Fe base alloy containing 12 % Cr (min)

What makes it stainless?

•Cr rich passive oxide film (adherent, tenacious and
impervious 5-25 A thick) formed on the surface which
isolates the material from the environment.

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1.4 CLASSIFICATION OF STAINLESS STEEL
5 main types based on microstructure.

•Ferritic stainless steel

•Martensitic Stainless Steel
•Austenitic Stainless Steel
•Duplex Stainless Steel
•Precipitation Hardenable Stainless Steel

Austenitic Stainless steel – Non- magnetic.

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A. Conventional Or Non-Nuclear Components
1. Mechanical Properties.
2. Corrosion Properties.
3. Fabricalbilities (Forming-Welding-Heat Treatment).
4. Cost.

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1.Neutron Absorption
2.Radiation Damage
-Irradiation Hardening
-Irradiation Creep
-Irradiation Growth

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1.6 Processing Structure Property Correlation

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 The following metallurgical characteristics control the
properties of materials:

A. Chemical Composition
Bulk/Local/Surface

B. Microstructure
Grain Size, Inclusions

C. Crystal Structure
FCC/BCC/HCP, Texture

D. Dislocation Density
Degree of Cold Work.

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a. Tensile Properties
b. Hardness
c. Bend Ductility
d. Toughness
e. Creep
f. Fatigue.

Properties a,b,c and d are called short-term property and are

evaluated for material qualification as per specification.
Properties e and f are called long term properties and
evaluated during development of material.

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UTS – Ultimate Tensile Strength
YS (0.2%) – Yield Strength (0.2% offset)
% Elongation = (L1-Lo)/Lo
% Reduction of Area (RA) = (Ao-A1)/Ao
Resilience: Energy Absorbed during Elastic
Deformation
Toughness: Energy Absorbed Before till fracture
Modulus of Elasticity: Slope of α-ε Curve in the
Elastic Limit (EL).

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Hardness : Resistance to deformation

Depth : Rockwell Hardness

Surface area : Brinell Hardness, Vickers hardness

Hardness values are not required for design calculation but they
are occasionally part of material specification.
Hardness are useful
(i) As a rapid test for knowing approximate tensile strength
[(UTS (kg/mm2)=0.36xBHN for steel in Normalized or annealed
condition]
[(UTS (kg/mm2)=0.32xBHN for steel in hardened and tempered
condition]
(ii) For designing brittle and ductile microstructure.
(Weld vs. HAZ vs. parent metal).

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 HARDNESS METHOD
Test Method Load Indentor Hardness
Rockwell 60, 100,
Steel ball Direct reading
150kg Diamond
Brinnel 500, 3000kg Steel ball Load/surface Area
Vickers 1-120 kg Diamond Load/Surface Area
Pyramid
Microhardness Upto 100 gm Diamond Load/Surface Area
Vickers Pyramid
Superficial 15, 30 45kg Steel Direct reading
Rockwell ball/Diamond
cone
Ultrasonic 800 gms Diamond Diamond Pyramid
Pyramid

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 For finding Toughness of Materials
 Toughness: Ability of material to absorb
energy & deform plastically before fracture.
 Toughness ↑- Resistance to Brittle Failure ↑

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CHARPY TEST Vs IZOD TEST

1. Charpy Test Specimen

-Specimen Size 55x10x10 mm.

2. Izod Test Specimen

-Specimen Size 75x10x10 mm.

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 NDTT is defined as the highest temperature at which a standard
notched specimen breaks in a brittle manner i.e., the material is
set to have nil ductility. Nil Ductility Transition Temperature
(NDTT) is determined as per ASTM E 208.

 At NDTT plus 33°C (60°F), Three Charpy V-notch specimen

results must exhibit a minimum of 68 J (50 ft.lb) of absorbed
energy and 0.89 mm (35 mil) of lateral expansion. RTNDT is
greater than or equal to the NDTT.

 Design code (ASME B&PV code section III) demands that

operating temperature should always be kept at least 60 F
above RTNDT to avoid brittle failure.

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1. Seamless Pipe (SMLS)
These pipes are extruded and have no longitudinal seam. There
is no weld and is the strongest of the three type pipes mentioned
here.

2. Submerged arc welded pipe (SAW)

These pipes are manufactured from plates, normally rolled and
seam welded together. The welding has a joint efficiency of 0.95.

3. Electric resistance welded pipe (ERW)

These pipes are manufactured from plates, where the seam
weld is done by electric resistance welding. The welding
efficiency is 0.8.

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1. Feeder Pipes in PHT System : SA333 Gr6 with 0.2% Cr (CS).
Impact requirement as per
ASME code.
2. Moderator System Piping : ASME SA 312 Type 304L (SS)
3. Secondary System Piping : SA106 Gr B (CS)
(No Impact requirement)
4. Service Water /Fire Water : Carbon Steel Pipelines (SA 53
system Pipelines GrB-Seamless) up to 300 NB
and SA 672 Class 12 &13
(welded) for 400 NB above
5. DM Water Pipeline : SA 312 TP 304 L.

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 Carbon Steel Pipe : Flow Accelerated Corrosion
(FAC), Microbial Attack.
 Stainless Steel Pipe : 1.Pitting corrosion,
2.Stress Corrosion Cracking
(Intergranular stress
Corrosion Cracking(IGSCC)
and TGSCC (Trangranular
stress corrosion cracking)
 Plastic Piping : Erosion by suspended
Particle.

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1. Chemical Factors

Oxygen, H2S, Chlorine Solubility, pH, Carbonate Solubility.

2. Physical factors

Velocity, Air bubbles, Suspended solids, temperature and

Pressure.

3. Biological Factors

Microorganisms in the water.

These factors alone or simultaneously produces various

forms of degradation in the piping.
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Microbiologically influenced corrosion (MIC) is becoming common
cause of corrosion failures in most of the Nuclear component
pipings.

Sulphate reducing bacteria (SRB) are responsible for many pipe

failures. SRB cause corrosion by damaging the base metal oxide
layer by accelerating the anodic corrosion, which results in pitting
and subsequently inducing the stress corrosion cracking of the
metal.

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MIC OF HEAT EXCHANGER PLATE NEAR GASKET

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 Corrosion resistance
 Oxidation resistance
 Helium Embrittlement (In Helium Cooled Reactors)
 Strength at elevated temperature
 Creep Rupture Strength
 Fatigue cracking resistance
 Thermal Creep
 Irradiation creep
 Irradiation Embrittlement
 Creep rupture strength

e.g. High temperature Piping material provides good creep

resistance. However, cost is higher.

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It refers to cracking caused by conjoint action of tensile stress and
a specific corrosive environment
Specificity for metal – environment such as
Stainless steel - Chloride solution
Brass, Cu - Ammonia solution
Carbon steel - Caustic solution
Monel - HF acid solution
There is a threshold stress or stress intensity factor for SCC to
occur
SCC path – Transgranular & Intergranular
(TGSCC) (IGSCC)
Control
Material selection.
Reduction of residual tensile stress.
Environment control. Mumbai April 2019
1.IGC: Corrosion localized at or near grain boundaries.
2. Mechanisms
1.Precipitation at Gbs.
2.Depletion of alloying elements near Gbs.
3.Segregation of impurity elements at Gbs.

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Sensitizing Carbide <12%
Non sensitizing Carbide >12%
Sensitizing temperature range - 450 to 8000C

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3.7 Detection of Sensitization
ASTM Evaluation tests for detecting susceptibility to IGC

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1.Material Control
 Material selection
 Microstructural modification
 Control of cold work
 Residual stress control
- Elimination of Tensile Stress
- Introduction of Surface Compressive Stress.

2. Environmental Control
 Removal of corrosive constituents (Oxygen, Moisture, Chlorine)
- Scavenger Type – removal of oxygen (N2H4)
 Use of inhibitor
-Vapour Phase inhibitor.

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3. Change of Operating Variables
 Lowering Temperature

 Decreasing Velocity

 Changing pH

4. Coatings – barrier between metal and environment.

 Electro deposition (Cr)

 Cladding (SS over CS)

 Hot dipping (Galvanising)

 Organic coating (Paints)

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 Change of Metal Electrode Potential
- Cathodic protection
Metal → Anode - Corrodes
↓
Cathode - Sacrificial Anode (Zn or Mg)
- Impressed Current (Underground pipeline)
 Anodic Protection

- only for those metals which show active – passive behaviour.

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5. Design Modifications
 Corrosion allowance in Wall Thickness
 Weld rather than rivet (susceptible to crevice corrosion)
 Design Piping for easy drainage (avoid stagnant solution)
 Avoid stress concentration (SCC)
 Avoid galvanic coupling
 Avoid sharp bend in piping

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5. PIPING MATERIAL SPECIFICATION

1. Unless otherwise specified, piping component wall thickness,

specified in the pipe classes are based only on design
consideration of pressure, temperature , and allowances for
corrosion and minus tolerance according to ASME B31.3
“Process Piping” or ASME B31.1 “Power Piping”

2. Piping component wall thickness do not include additional

thickness required to compensate for design considerations
such as thermal loads due to restrains, live load, hydraulic
shock or load and sources from other caused all of which
must be considered in the design of piping systems.

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5.1.1 Wall Thickness
Wall thickness as determined by design formulas is
increased to provide :
1. Corrosion Allowance.
2. Tolerances for threading and machining,
thinning allowance when pipe is to be Bent.
3. Pipe Manufacturer's manufacturing tolerances.

5.1.2 Corrosion and erosion allowances

Corrosion and erosion allowances are not set
forth in the code, but are left to the discretion of the
designer.

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The following corrosion allowances are specified as minimum
requirement.
Material Corrosion
Allowance
(mm)
Carbon steel and alloy up to 9 Cr-Mo in 1.6
Dry service
Carbon steel and alloy up to 9 Cr-Mo in 3.2
wet service
Galvanized Steel 1.6
Stainless Steel 0
Non-Metal such as GRP, HDPE and PVC 0

In special cases a greater corrosion allowance may be

required.

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1. Pipe which is to be threaded shall have an allowance equal
to the thread depth added to the calculated wall thickness.

2. For machine surfaces or grooves where the tolerance is not

specified, the tolerance shall be assumed to be 0.5 mm in
addition to the specified depth cut.

5.3 MANUFACTURING TOLERANCES

The manufacturers minus tolerance for wall thickness is

added to the calculated wall thickness in accordance with
applicable ASTM .

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Where dual grade materials i.e. 316/316L or 304/304L Stainless
steel is available, they shall be used. The corresponding allowable
stresses of the higher strength material shall be used in
calculating wall thicknesses and the pressure limits of the class.
5.5 Carbon Content
Carbon steel piping requiring welding or heat cutting (torch) shall
have carbon content less than 0.33 wt%.
5.6 Austenitic stainless steel
Austenitic stainless steel material (pipe, fitting, flange, plate,
forging, casting, etc.) shall be furnished in the solution annealed
condition.

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1. Material requirement
The steel is clean, homogeneous and it is produced by fine grain
melting practice and is fully killed. The steel is subjected to
vacuum treatment/refinement is preferred.

2. Chemical Composition
In the chemical composition, restriction is provided on S, P, Cr and
impurity elements.

In the forging, chemical composition control is also required for

the following elements.
Tin, Arsenic, antimony, Nitrogen.

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All products forms are supplied in the Normalized state. Product is
supplied in the pickled condition.
 Supplementary Requirements

1. Metal macro structure/etch test.

2. Hardness test.
3. Transverse tension test.
4. Flattening test (As per SA530).
5. Burst test
6. Hydrostatic test
7. Liquid penetrant examination
8. Magnetic particle examination
9. Ultrasonic examination
10.No repair by Welding

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5. Specification SA 106 is used for seamless carbon
steel pipe for high temperature service.
The material specification is as follows.
1. Grade
2. Manufacture (Hot finished or cold drawn).
3. Size and weight class or Schedule, OD, ID, wall
thickness
4. Special Inside and outside tolerance pipe.
5. Length
6. Test reports
7. Specification designation (106B or 106 M)
8. Any Special requirement.

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 SA 106 Requirements
1. Chemical Composition.
2. Tensile requirement.
3. Bending requirement.
4. Hydrostatic test.

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7.1 Selection of Piping System
i. The most commonly used material for metal piping system is
carbon steel. It generally results in most economical system.
ii. However, Stainless steel is selected as result of reduced
corrosion and low contamination which is desirable in Nuclear
application.
iii. Because of excellent strength charactertics, stainless steel
piping can withstand higher pressures, or a full vacuum, over
wide temperature range which in turn means greater degree of
safety.

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iv. Because of their high temperature charactertics, stainless steel
pipes are readily steam jacketed
V. Stainless Steel Piping is more resistant than plastic in the
event of fire.
Vi. The excellent ductility of stainless steel enables extensive
forming operations.
Vii. Stainless steel pipes are available as either welded or
seamless.
Viii. It has good abrasion resistance.
ix. Good heat transfer properties as compared to non metals.
X. It can be cleaned by number of cleaning agents.

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7.2 Limitations of Stainless Steel Material
i. Pitting
ii. Crevice
iii. Stress Corrosion Cracking
iv. Intergranular corrosion

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1. High temperature SS piping is used in Indian PFBR reactor.

2. 316 LN is widely used material for primary pressure piping for

temperature>723 K (4500C).

3. In Indian PFBR, stainless steel (SS) of type 316LN is used in

primary and secondary loops.

4. Nitrogen alloying to 316 SS enhances design life of the reactor

components.
5. The operating pressures are relatively lower in PFBR,
however, thermo-mechanical loads are very important.

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Sea Water is Desalinated for
1.Domestic Requirements
2.Construction Requirements
3.Industrial Demands etc.
Desalination / Power / Chemical /Oil and Gas Plants
are Being Built along the Coasts of Red Sea and Arabian Gulf.

Seawater of Arabian Gulf and Red Sea

1. Total Dissolved solid (TDS) ranges from 40000 to 65000 ppm.
2. It contains dissolved gases.
3. Decaying organics, In-organic and other aggressive elements.

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FRP PIPING FOR SEA WATER APPLICATION

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1. General Corrosion attack of the material.
2. Impingement attack.
3. Erosion by Suspended Particles.
4. Crevice Corrosion
5. Stress Corrosion Cracking (SCC)

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1. Cost.
2. Plant life desired.
3. Material Compatibility.
4. Maintenance Capabilities.
5. Ease of availability.
6. Overall life Cycle Capital Cost Constraints.
7. Design and Operating Conditions.

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 Properties FRP Polyester GRE Epoxy
Piping Piping
Resin Polyester Epoxy

Temperature Up to 65 to 900C Up to 1500C

Pressure Gravity to 40 Gravity to 200

bar/ full vacuum bar/ full vacuum
Can handle All-moderate All-high
Corrosive fluid Corrosive fluid

GRE: Glassfibre Reinforced Plastic

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8.5 COEFFICIENT OF THERMAL EXPANSION

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8.6 THERMAL CONDUCTIVITY

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8.7 SAVING TIME AND MONEY –LIFE CYCLE COST

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GRP Pipes are suitable for All Applications better than that of
Traditional Materials.

 No Maintenance, INSTALL it FORGET it.

 Not in Theory but Exists over 30 Years.
 Commercially Viable.
 Greater Flexibilities.
 Need to Adopt Now in All Applications.

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 Materials play an important part in the design, fabrication and
trouble free operation of Pipings.

 Use of piping material depends on the application

requirements.

 Various tests as per ASTM standards are used to determine

mechanical properties of material and corrosion performance
of piping material for fitness in service.

 There is different degradation mechanism for different piping

materials.

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 Feedback’ from fabrication, operation and R&D activities will
help for proper material selection .

 Selection and Qualification of materials must, there, is an

ongoing process. There is also a need to develop more
‘Forgiving’ materials which are more tolerant to flaws, more
resistant to environmental attack and more resistant to radiation
damage In Nuclear Industries for Pipings.

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