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Fatigue of Metals - WordP

(a) Given: Stress = 27.6 MPa, Minimum creep rate = 3.6 x 10-5 %/s Using Monkman-Grant relationship: log(tr) + Clog(3.6 x 10-5) = K log(tr) = K - Clog(3.6 x 10-5) tr = antilog(K - Clog(3.6 x 10-5)) = 5400 s (b) Given: Required time to fracture = 12000 s Using Monkman-Grant relationship: log(12000) + Clog(?) = K ? = antilog(K - log(12000) -

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62 views31 pages

Fatigue of Metals - WordP

(a) Given: Stress = 27.6 MPa, Minimum creep rate = 3.6 x 10-5 %/s Using Monkman-Grant relationship: log(tr) + Clog(3.6 x 10-5) = K log(tr) = K - Clog(3.6 x 10-5) tr = antilog(K - Clog(3.6 x 10-5)) = 5400 s (b) Given: Required time to fracture = 12000 s Using Monkman-Grant relationship: log(12000) + Clog(?) = K ? = antilog(K - log(12000) -

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BMFB 4283

NDT & FAILURE ANALYSIS

Lectures for Week 11

Prof. Qumrul Ahsan, PhD


Department of Engineering Materials
Faculty of Manufacturing Engineering
Issues to address

11.0 Creep and Stress Rupture

11.1 Introduction
11.2 Creep Tests
10.3 Mechanism of Creep Deformation and
10.4 Fracture at Elevated Temperature
10.5 Creep Data
/G > 10-2

10-4< /G <10-2

/G < 10-4


• Ductile fracture initiated at inclusions and
second-phase particles
• Transgranular fracture due to nucleation of
voids and void coalescence are postponed
• Grain boundary sliding , wedge crack s and
voids growth -> intergranular fracture
• At high temp, matl necks down to rupture
( absence of nucleation and coalescence of
voids)
• Creep cavitation : nucleation and growth of grain-boundary voids
(third stage)
• Extremely high stresses normal to a grain boundary are required to
nucleate a cavity.
• Cavity growth will occur if
Mechanisms of intergranular nucleation

• Two types of intergranular cracks


:
• Wedge-shaped cracks (w-type cracking)
• Round or elliptical cavities (r-type
crack)

.
(From W.D. Nix and J. C. Gibeling, in Flow and Fracture at ElevatedTemperatures,
ed, R. Raj (Metals Park, Ohio: ASM, 1985).)
Critical Factors in Creep
• The rate of damage or strain rate

• Threshold temperatures

• Low creep ductility is:

– More severe for higher tensile


strength materials and welds.
– More likely in a coarse-
grained material than a fine-
grained material.
– Promoted by certain carbide
types in some Cr-Mo steels.

22
Creep and Stress Rupture Affected Units
or Equipment
• Heater tubes, tube supports, hangers and other furnace
internals.

• Piping and equipment, such as hot-wall catalytic reforming


reactors and furnace tubes, hydrogen reforming furnace tubes

• Weld and HAZ of Catalytic Reformer Tubes and Reactors

• Welds of dissimilar materials (ferritic to austenitic welds)

• All boiler and fired heater tubes are susceptible.

23
Appearance or Morphology of Creep
Damage
• Change in dimensions
• Creep voiding
• Change in microstructure (SEM, OM)
• Change in hardness

Replication and
24
hardness
Dimensional
Prevention / Mitigation of Creep
• To prevent creep damage - minimize the metal temperature

• To avoid stress concentrators

• Low creep ductility can be minimized by the careful selection of


chemistry for low alloy materials (e.g. PWHT of Cr-Mo Steel)

• Creep damage is not reversible - repair or replace the damaged


component.

• Alloys with improved creep resistance may be required for longer


life (e.g. Nb, V, Mo, Ti)

• Visual inspection followed by thickness measurements may be


required to assess remaining life of heater tubes

25
Typical fractograph of creep crack growth

Intergranular Mixed Mode : Intergranular and


Transgranular
• Creep strength could be estimated from rupture
strength with sufficient accuracy for design purposes
• Monkman and Grant relationship
logtr + Clogєs = K, where K and C are constant and tr
is rupture life and єs is the minimum creep rate
Creep properties of copper tested at 688K. Make an
estimate of (a) the rupture time at 27.6 MPa and (b) the
stress required to give a rupture time of 12000 s
Stress , MPa Minimum creep rate, Time to fracture, s
% s-1
48.3 3.0 x10-4 5640
34.5 7.5 x10-5 2640
27.6 3.6 x10-5 -

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