Creep and stress rupture Subjects of interest Objectives / Introduction The high temperature materials problem Temperature dependent mechanical behaviour Creep test Stress rupture test Structural change during creep Mechanisms of creep deformation racture at elevated temperature !igh temperature allo"s Ma"#$ug %&&' Objectives This chapter provides the understanding of deformation and fracture behaviour of material at high temperature( Creep and stress rupture tests )ill be compared such that the interpretation of test data )ill be discussed for engineering applications( This )ill lead to the selection of metal and allo"s for desired uses at high temperature( Introduction Introduction http*//che)eb(tamu(edu/orgs !igh temperature applications )))(bv(com Subjected to high stress at high temperature http*//en()i+ipedia(org Oil refiner" Steam po)er plant )))(ideas#eng(com Steam turbine used in po)er plant ,rocess plant Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol !igh temperature materials problem !igh temperature materials problem Temp $toms move faster diffusion#controlled process( This affects mechanical properties of materials( .reater mobilit" of dislocations /climb0( Increased amount of vacancies( 1eformation at grain boundaries( Metallurgical changes2 i(e(2 phase transformation2 precipitation2 o3idation2 recr"stallisation( !igh temperature materials/allo"s Improved high temperature strength( .ood o3idation resistance( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol 4hat is creep5 4hat is creep5 Creep occurs )hen a metal is subjected to a constant tensile load at an elevated temperature( -ndergo a time#dependent increase in length( $t )hich temperature that material )ill creep5 Since materials have its o)n different melting point2 each )ill creep )hen the homologous temperature 6 &(7( Testing temperature !omologous temp 8 6 &(7 Melting temperature The creep test measure the dimensional changes )hich occur )hen subjected to high temperature( The rupture test measures the effect of temperature on the long# time load bearing characteristics( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Creep test Creep test )))(a3elproducts(com The creep test is carried out b" appl"ing a constant load to a tensile specimen maintained at a constant temperature2 /according to $STM 913:#'&0( Creep test setting T"pical creep curve )))(t)i(co(u+ Schematic creep test Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol The creep curve The creep curve $ t"pical creep curve sho)s three distinct stages )ith different creep rates( $fter an initial rapid elongation o2 the creep rate decrease )ith time until reaching the stead" state( 10 ,rimar" creep provides decreasing creep rate( %0 Secondar" creep gives the representing constant creep rate( 30 Tertiar" creep "ields a rapid creep rate till failure( The constant creep rate in the second step represent the creep rate of the material( T"pical creep curve sho)ing three stages of creep ;otes* < curve is obtained )hen the stress rather than the load is maintained( o is instantaneous strain on loading )hich is partl" recoverable )ith time /anelastic0 and partl" nonrecoverable )ith time /plastic0( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Three stages of creep Three stages of creep 10 ,rimar" creep is a period of transient creep( The creep resistance of the material increases due to material deformation( ,redominate at lo) temperature test such as in the creep of lead at =T( %0 Secondar" creep provides a nearl" constant creep rate( The average value of the creep rate during this period is called the minimum creep rate( 30 Tertiar" creep sho)s a rapid increase in the creep rate due to effectivel" reduced cross#sectional area of the specimen( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol 9ffect of stress on creep curves at 9ffect of stress on creep curves at constant temperature constant temperature The shape of creep curve )ill slightl" change according to the applied stress at a constant temperature( $pplied stress Strain Creep rate Temp Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol The stress rupture test The stress rupture test Creep test Stress rupture test >oad >o) load high load Creep rate minimum creep rate high creep rate Test period %&&&&&& h 1&&& h Total strain &(7? 7&? Strain gauge .ood strain Simpler strain measuring devices measuring devices The rupture test in carried out in a similar manner to the creep test but at a higher stress level until the specimen fails and the time at failure is measured( =upture strength and failure time are plotted2 normall" sho)ing a straight line( Changing of the slope indicates structural changes in the material2 i(e(2 transgranular intergranular fracture2 o3idation2 recr"stallisation2 grain gro)th2 spheroidi@ation2 precipitation( 1irect application in design( Stress rupture# time data on log#log scale Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Structural changes during creep Structural changes during creep There are three principal deformation processes at elevated temperature( 10 1eformation b" slip More slip s"stems operate at high temperature Slip bands are coarser and )idel" spaced( %0 Subgrain formation Creep deformation produces imhomoginiet" especiall" around grain boundaries2 allo)ing dislocations to arrange themselves into a lo)#angle grain boundar"( 9as" for metals )ith high stac+ing false energ"( Creep rate and total strain relationship 1ifferent creep rates result from changes in internal structure of the materials )ith creep rate and time( 30 .rain boundar" sliding ,roduced b" shear process and promoted b" increasing temperature/or decreasing strain rate( =esults in grain boundar" folding or grain boundar" migration( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Mechanisms of creep deformation Mechanisms of creep deformation The chief creep deformation mechanisms can be grouped intoA 10 1islocation glide Involves dislocation moving along slip planes and overcoming barriers b" thermal activation( Occurs at high stress( %0 1islocation creep Involves dislocation movement to overcome barriers b" diffusion of vacancies or interstitials( 30 1iffusion creep Involves the flo) of vacancies and interstitials through a cr"stal under the influence of applied stress( B0 .rain boundar" sliding Involves the sliding of grains past each other( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol 1eformation mechanism maps 1eformation mechanism maps The various regions of the map indicate the dominant deformation mechanism for the combination of stress and temperature( $t the boundar"2 t)o mechanisms occur( Simplified deformation mechanism map( ;ote* . is the shear modulus Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol $ctivated energ" for stead"# #state creep state creep $ctivated energ" for stead" Stead"#state creep deformation predominates at temperatures above &(7Tm( Stead" state creep can be e3pressed b" 9C(1 =T D s $e / 4here D 8 the activated energ" for the rate#controlling process $ 8 the material structural constant T 8 the absolute temperature = 8 the universal gas constant The activated energ" D can be calculated b" assuming the temperature interval is small so that the creep mechanisms is not e3pected to change( e e $ / / =T D =T D % 1 % 1 0 / ln/ = D % 1 0 / 1 / 1 / Superplasticit" Superplasticit" Superplasticit" is the abilit" to )ithstand ver" large deformation in tension )ithout nec+ing( .ive elongation 6 1&&&?( Materials )ith high strain rate sensitivit" /m0 at high temperature /T6&(7Tm0 superplasticit" Materials characteristics* fine grain si@e /E1& m0 )ith the presence of second phase of similar strength to the matri3 to inhibit grain gro)th and to avoid e3tensive internal cavit" formation( .rain boundar" should be high angle and mobile to promote grain boundar" sliding and to avoid the formation of local stress concentration respectivel"( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Superplastic flo) flo) Superplastic The superplastic flo) is given b" b1 % or grain boundar" diffusion 1& F 3 > 9 gb 1 % 1& % or lattice self#diffusion 9C(3 9C(3 : % > 9 o 4here > is the mean linear intercept measure of grain si@e( in this case n 8 %2 m 8 &(7 The predominant mechanism for superplasticit" deformation is grain#boundar" sliding accommodated b" slip( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol racture at elevated temperature racture at elevated temperature Temp Transgranular fracture Intergranular fracture .rain boundaries are )ea+er than slip planes( Slip planes are )ea+er than grain boundaries Transgranular cleavage fracture .rain boundar" fracture The formation of intergranular crac+ b" grain boundar" sliding Transgranular microvoid coalescence ;ote* at T just belo) Trecr"s2 ductilit" drops due to grain boundar" sliding intergranular failure( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol 9Cuicohesive temperature temperature 9Cuicohesive .rain Strength of .< 8 grain at the eCuicohesive temperature /9CT0( .rain boundar" Strain rate 9CT Temp 9CT Intergranular fracture Transgranular fracture Increasing the tendenc" for intergranular failure <elo) 9CT small grain si@ed material is stronger due to high densit" of grain boundaries to improve strength( $bove 9CT large grain si@ed material is stronger due to less tendenc" for grain boundar" sliding( ;ote* Single cr"stal structure is therefore appreciable for high temperature applications2 i(e(2 nic+el base allo" single cr"stal turbine blade( racture mechanism map for nic+el Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol !igh temperature allo"s !igh temperature allo"s !igh temperature allo"s are comple3 in their microstructures to obtain the reCuired properties at service temperatures( !igh melting point allo"s normall" has high creep resistance( Metals )ith high stac+ing false energ" eas" for slip creep( ine precipitates having high thermal stabilit" are necessar" for high creep resistance /prevent grain gro)th0( 93* /10 ;ic+el base allo" containing fine precipitates of intermetallic compounds ;i3$l2 ;I3Ti or ;i3/$l2Ti02 /%0 Creep resistance steels containing fine carbides GC2 TiC2 ;bC2 Mo%C or Cr%3CH( 1ra)bac+s 1ifficult to fabricate b" hot#)or+ing2 cold )or+ing or )elding( !ighl" allo"ed metals are difficult to produced b" precision casting( Microstructure of nic+el base allo" Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Composition of some high Composition of some high temperature allo"s temperature allo"s Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol ,resentation of engineering ,resentation of engineering creep data creep data Creep strength is defined as the stress at a given temperature2 )hich produces a stead"#state creep rate /1 to 1&#F s#1(0 Stress vs minimum creep rate >og#log plot is used so that the e3trapolation of one log#c"cle represents a tenfold change( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol Creep data Creep data Creep data can also be presented as a plot of stress and time to produce different amounts of total strain( The upper most curve is the stress rupture curve( The percentage beside each data point is the percentage reduction at failure( 1eformation time curve Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol 93ample* 1etermine the )or+ing stress at H&&oC and F&&oC for t"pe 31H stainless steel if the design criterion is a creep strength based on 1 percent e3tension in 1&&& hr( -se a factor of safet" of 3( 1& 7 1? creep in 1&&&h 1& F ( % 1& s s h 1 : 1 1 7 3H&& rom stress and minimum creep rate curve2 the )or+ing stress using the safet" factor of 3 can be obtained in the table belo)( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol 93ample* or the stress#minimum creep rate curve2 determine the activation energ" for creep at a stress of 1&& M,a( 1& A :'3 '&& s I C T at 1 F % % o o 1& A 1&'3 F&& s I C T at 1 7 1 % rom 9C(% 0 1& ln/ 0 3 ( F / 0 / ln/ I Jmol = 3 1 1 7::+Jmol D % 1 1 1&'3 / 1 :'3 / 1 0 / 1 / 1 / T T 1 % Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol =eference =eference 1ieter2 .(9(2 Mechanical metallurg"2 1:FF2 SI metric edition2 Mc.ra)#!ill2 IS<; &#&'#1&&B&H#F( Suranaree -niversit" of Technolog" Ma"#$ug %&&' Tapan" -domphol