Creep-Fatigue in 9-12Cr Steels OMMI (Vol.

3, Issue 2) August 2004

www.ommi.co.uk


CREEP, CREEP-FATIGUE CRACK INITIATION AND GROWTH IN 9-
12% CHROMIUM STEELS

T Gengenbach & A Klenk, MPA, University of Stuttgart, Germany



Abstract

There are various methods to assess crack initiation and crack growth behaviour of
components under creep and creep-fatigue loading. The programme system HT-RISS was
developed to support calculations aimed to determine the behaviour of a crack under creep or
creep-fatigue loading using methods based on stress-intensity factor K, e.g. the 2-criteria
diagram or C*-Integral. This paper describes the steps which have to be performed to assess
crack initiation and growth in a component using this programme system. First the size of the
maximum initial defect in a specimen or in a component has to be estimated and the necessary
fracture mechanics parameters have to be determined. Then the time for creep crack initiation
and creep crack growth is calculated. Using these values, a prediction of life-time and
necessary inspection intervals is possible. For demonstration, the crack assessment of a
component-like specimen and a component is shown.


Introduction

During fabrication of components for modern power plants the development of natural
defects, e.g. non-metallic inclusions and inhomogeneities, is not completely avoidable.
However, components like rotors of turbines are exposed to high and complex loading under
high temperatures. Therefore, a suitable calculation process is necessary in order to assess
existing defects in components. There are various methods to assess crack initiation and crack
growth behaviour of components under creep and creep-fatigue behaviour. The programme
system HT-RISS [1] was developed to support calculations aimed to determine the
behaviour of a crack under creep or creep-fatigue loading using methods based on stress-
intensity factor K, e.g. the 2-criteria diagram [2] or C*-Integral. In the following, details for
the procedure using this programme system are given starting with non-destructive testing
methods in order to determine the initial size of a defect and ending up with predicting the
crack initiation time and crack growth rate. For demonstration, the assessments of a large
sized double edge notched tension specimen with a thickness of 60 mm (DENT60) made of
10% chromium steel and of a 12Cr header are described [3].


Determination of the size of initial defects

Non-destructive methods are used in order to determine the size of internal defects. Magnetic
particle inspection is used for analysing flaws at the surface. Using these methods it is
possible to detect the size of an initial defect. If no defects are detected, it is possible to
estimate the maximum size of defects that are too small to be detected. In [3] an experimental
study is described. Different artificial cracks eroded at the nozzle corner position of a header
(Figure 1) were investigated by ultrasonics. This study showed that the minimum size of a
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

2
crack at this position which can be detected reliably is approximately 1 mm. For the 0.7 mm
crack no reliable results could be obtained.

Using the estimated size of the maximum initial defect the effective fracture mechanics
parameters (K, C*) can be determined. These are the basic input parameters required to carry
out the crack analyses described in the following sections.


Material properties describing crack initiation and growth and component crack
behaviour

Path independent integral C* and stress intensity factor K
I
are two parameters often used for
describing crack initiation and growth under creep conditions [4-7]:
In linear-elastic fracture mechanics the stress intensity factor K
I
is generally used.
Additionally components with predominantly linear elastic behaviour and only a small
plastic zone at the crack tip can be assessed using stress intensity factor K
I
.
Components with stationary creep (not only at the crack tip) are assessed using
integral C*.
For the assessment, the material behaviour described in terms of one of those parameters must
be known. Investigations in the long-term range which are necessary in cases of creep and
creep-fatigue conditions have been made in various EU- and national projects, e.g. [8]. In [1]
a consolidated database comprising various forged, cast and piping steels, e.g. 1Cr-steels,
12Cr and 9Cr steels as well as newly developed 10-11Cr steels which were investigated in a
large series of research projects [9-12] was established. This database can be used in
combination with the software modules in the programme system HT-RISS.

For the assessment of crack initiation the usage of two criteria approaches promised to be the
appropriate way to treat the problem of different types of damage behaviour in components
[4, 13]. A detailed comparison of the methods available is given in [14]. In the programme
system HT-RISS the two-criteria-diagram [2] is implemented. Stress intensity factors for
many types of component are available in the literature. This is a major advantage of using
stress intensity factor K
I
. However, under creep conditions K
I
is not valid without further
considerations. Beneath K
I
, describing the situation at the crack tip,
n pl
, describing the
ligament stress, has to be taken into account. The Two-Criteria-Diagram has been developed
for this kind of assessment [2, 14]. In Figure 2 an example for the Two-Criteria-Diagram is
shown. In Figure 3 the normalised values R for stress and stress intensity used in the Two-
Criteria-Diagram are described.

Necessary material data for the application of the Two-Criteria-Diagram are creep rupture
time and creep crack initiation data. Creep crack initiation data available in the database
mentioned above have been obtained with a variety of specimen types (Figures 4 and 5). For
basic assessments data obtained with Cs25 (side grooved compact tension specimens with a
thickness of 25mm) are used.


Examples for predicting crack initiation and growth using HT-RISS

The software HT-RISS for predicting creep crack behaviour has been developed by the
German creep crack behaviour research group W14 (mainly consisting of MPA University of
Stuttgart, IfW Darmstadt and power plant industry). HT-RISS consists of two parts. Part
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

3
one contains the database system with material data whereas part two consists of several
calculation modules for predicting crack initiation and crack growth.

Creep crack initiation and growth data depending on K
I
and C* for different materials and
specimens have been determined. Additionally rupture time curves have been acquired [11].
This material data is stored in the database of HT-RISS.

In the past, creep-fatigue crack experiments with different materials have been accomplished
in several research projects at MPA University of Stuttgart. One of the material classes under
investigation is the group of 9-11% chromium steels. Particularly the forged steel
X12CrMoWVNbN10-1-1/1A (X12) and the cast steel GX12CrMoWVNbN10-1-1/2A
(GX12) have been under investigation. In the following, the cast steel is considered. The
calculations were done using material data stored in the database of HT-RISS, which is
based mainly on Cs25 specimens. Using HT-RISS for predicting crack initiation and crack
growth of Cs25 specimens a good prediction could be made, as the calculation is based on
crack data of the same type of specimens.

In order to carry out a more general verification of the calculation modules in HT-RISS,
creep crack initiation and growth of a component-specimen (large Ds60-specimen, thickness
60 mm, see Figure 6) is predicted. For this purpose, the database and the calculation modules
implemented in HT-RISS are applied. The results are compared with the experimental
values.

The creep crack initiation time was calculated using a conservative (lower bound) and a mean
crack initiation curve C*=f(t
i
). The predicted initiation time (2000h for conservative and
3000h for mean calculation) is compared with the experimental initiation time (7000h) in
Figure 7. Both calculated results are conservative, as the calculation is based on crack data
from Cs25-specimens, which gives conservative initiation times compared with larger
specimens.

Creep crack growth was simulated using a conservative and a mean crack growth curve
da/dt=f(C*). In Figure 8 the crack growth results are presented. For example, if a crack
propagation of a = 2.5 mm in the component is just acceptable, the experimental time for a
crack propagation of the accepted a = 2.5 mm is 10,000h. The result for the mean creep
crack growth calculation is 9000h (for a = 2.5 mm) and matches the experimental result
well. Whereas the conservative creep crack growth curve gives a conservative prediction of
5000h for a crack propagation of a = 2.5 mm. Using these values, a prediction of life-time
and necessary inspection intervals is possible.

The header shown in Figure 1 was made of 12Cr steel (X20CrMoV12-1) and operated under
internal pressure at service temperature 490C (stationary conditions). The respective
membrane stress is 107MPa according to TRD-calculation [3]. Since there were no material
data available for the service temperature, extrapolation using an Arrhenius equation as
described in [1] was performed. For these conditions, an assessment was made assuming
conservatively an initial crack of length 3 mm. A crack initiation time of 16,000h was
conservatively determined. Additionally 2 mm crack growth was predicted after 300,000h
using the mean curve of crack propagation data (Figure 9). When the conservative curve was
used for the same crack propagation a service time of 20,000h was determined. For these
calculations, a factor of 2.5 was assumed for the stress calculation in order to take into
account local stress conditions.
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

4
Influencing effects on material properties describing crack initiation and growth

So far assessments are based on material data obtained with standard specimens. However,
the experience with various specimen types and under different loading conditions shows that
there are strong influences of specimen geometry, i.e. specimen thickness or different ratios of
stress intensity factor to net stress.

For example, results found in several research projects show a strong influence of specimen
thickness on crack initiation behaviour. This effect is shown for the steels X12 and GX12
using a K
I0
versus t
i
diagram in Figure 10 and Figure 11. This effect is due to increasing strain
constraint in larger specimens and is still under investigation.

The influence of hold time during creep-fatigue loading is shown in the C* versus t
i
diagram
in Figure 12. In Figure 13 the same influence of hold time during creep-fatigue loading is
demonstrated in a K
I0
=f(t
i
) diagram. Both diagrams show that creep-fatigue loading
conditions with long hold times (i.e. t
H
approx. 3 h) lead to initiation times matching
approximately the results obtained from applying creep loadings without fatigue interaction.
Applying creep-fatigue loading with short hold times (i.e. t
H
approx. 0,3 h) leads to crack
behaviour matching approximately the results obtained from applying fatigue loading without
creep interaction. This effect has been examined in several research projects [1,11] by using
creep-fatigue accumulation and is still under investigation in some current research projects
[12,15].

Further influence of stress ratio in high temperature fatigue and creep-fatigue loading is
studied in these research projects using approaches for an effective K
I
depending on the
stress ratio R, i.e. K
I,eff
= f(K
I
, R).


Conclusions

The program HT-RISS is a suitable tool for predicting creep/creep-fatigue crack initiation
and creep/creep-fatigue crack growth. Conservative and mean creep crack initiation curves
based on Cs25 specimens have been implemented in the database system. Additionally, creep
crack growth curves are available. K
I
and C* are used as fracture mechanics parameters.

Further investigations are necessary and will concentrate on determining the effect of
influencing factors such as hold time, stress ratio and specimen thickness (with respect to
constraint).


Acknowledgements

This paper is based on results of various research projects in co-operation of MPA University
of Stuttgart together with Institut fr Werkstoffkunde, Technical University of Darmstadt and
steel and turbine manufacturers (Alstom Power Baden, Switzerland, Siemens PG,
Saarschmiede). The work was funded by the Forschungsvereinigung der Arbeitsgemeinschaft
der Eisen und Metall verarbeitenden Industrie e.V. (AVIF) under project numbers AVIF-
No. A141 and A202. The authors would like to express their sincere gratitude to the funding
organisations and all partners for their contributions.

Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

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References

[1] C. Berger, K. Maile, A. Scholz, A. Klenk, T. Mao, T. Gengenbach: Berechnung von
Risseinleitung und Rissfortschritt in Hochtemperaturbauteilen, Schlussbericht zum
AVIF-Forschungsvorhaben Nr. A141 (2002)
[2] J. Ewald, S. Sheng, A. Klenk, G. Schellenberg: Engineering guide to assessment of
creep crack initiation on components by Two-Criteria-Diagram, 2nd International
HIDA-Conference, October 04-06 2000, Stuttgart
[3] K. Maile, A. Jovanovic, L. Stumpfrock und A. Klenk: Praktische Anwendung
bruchmechanischer Verfahren zur Bestimmung von kritischer Risstiefe sowie
Ermdungs- und Kriechrisswachstum auf einen Rohrleitungsstutzen nach langzeitiger
Betriebsbeanspruchung, 34. Tagung des DVM-Arbeitskreises Bruchvorgnge, 19-
20.2.2002, Freiberg, DVM-Bericht 234 (2002)
[4] J. Ewald, K. H. Keienburg: A two criteria diagram for creep crack initiation,
International Conference on Creep, April 14-18 1986, Tokyo
[5] S.R. Holdsworth: Initiation and early growth of creep cracks from pre-existing defects.
Materials at High Temperatures, Vol.10, No.2, pp. 127/37, (1992)
[6] H. Riedel and J. R. Rice: ASTM STP 700. pp. 112-130 (1980)
[7] K. M. Nikbin. D. J. Smith and G. A. Webster: Proc. ASME, Int Conf on Advances in
Life Prediction Methods, Albany, pp. 249/58, (1983)
[8] I. A. Shibli: Overview on the HIDA Project and Progress, 2nd International HIDA-
Conference, 4-6 October 2002, Stuttgart, Paper S0-1
[9] E. Roos, K. Maile, C. Berger, J. Granacher: Rissverhalten typischer warmfester
Kraftwerksbausthle im Kriechermdungsbereich. Schlussbericht zum AiF-
Forschungsvorhaben Nr. 10395 I/II des Instituts fr Werkstoffkunde der TU Darmstadt
und der Staatlichen Materialprfungsanstalt, Universitt Stuttgart (1999)
[10] C. Berger, E. Roos, A. Scholz, K. Maile, F. Mller, W. Stadtmller:
Hochtemperaturrissverhalten der neuen 600 C-Sthle fr Wellen und Gehuse von
Dampfturbinen, Schlussbericht zum AVIF-Forschungsvorhaben Nr. A127 (2002)
[11] Roos, E., K. Maile, C. Berger, J. Granacher: Kriechrissverhalten ausgewhlter
Kraftwerkssthle in erweiterten praxisnahem Parameterbereich. Schlussbericht zum
AVIF-Forschungsvorhaben Nr. A78 des Instituts fr Werkstoffkunde der TU Darmstadt
und der Staatlichen Materialprfungsanstalt, Universitt Stuttgart (1999)
[12] Kriech- und Kriechermdungsrissverhalten moderner Kraftwerkssthle im
Langzeitbereich, laufendes AVIF-Forschungsvorhaben Nr. A178, estimated completion
2005
[13] R.A. Ainsworth et al.: Assessment procedure for defects under steady loading. Vol.4 of
R5 Procedure for the high temperature response of structures (1990)
[14] J. Ewald and S. Sheng: The two criteria diagram for creep crack initiation and its
application to an IP-turbine. Materials at High Temperatures, Vol.15, pp. 281/88 (1998)
[15] Programmgesttzte fortschrittliche Kriech- und Kriechermdungsrissbeschreibung fr
typische langzeitbeanspruchte Kraftwerksbauteile, AVIF-Forschungsvorhaben Nr.
A202, estimated completion 2005
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

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Figures

Figure 1: Determination of the size of a crack in the nozzle corner [2]
0.0
0.5
1.0
1.5
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
R
K
= K
I id0
/ K
Ii
R

n

p
l

/

R
m
t
boundary line crack / no crack
boundary line for specimen /
components with large dimensions
(B > 50 mm)
L
i
g
a
m
e
n
t

d
a
m
a
g
e
(
b
u
r
s
t
)
R

/R
K
= 2
R

/R
K
= 0,5
S
t
r
e
s
s

-

(
f
a
r
f
i
e
l
d
-
)

r
a
t
i
o
Crack tip ratio
Crack tip damage
(lekage)
no crack
Mixed
mode
damage

Figure 2: Two-Criteria-Diagram for creep crack initiation (creep ductile materials)

Figure 3: Explanation of the normalised values R for stress and stress intensity
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

7
2 a
W
a
2 W
a
W
a
2 W
B

Figure 4: Geometry of typical fracture mechanics specimens: CNT (Centre Notch Tension),
SENT (Single Edge Notch Tension), DENT (Double Edge Notch Tension) and
CT (Compact Tension)
v
v
2
2
v
v
a
0 BN
a
F, v
F, v
W B
F
F
2W B
BN
0

Figure 5: Dimensions of used fracture mechanics specimens
2 W
a

Figure 6: DENT-specimen
Cs25 Cs50 Ds20 Ds60
B (mm) 25 50 20 60
B
net
(mm) 20 40 16 48
W (mm) 50 100 5,25 50
a
0
/W 0.55 0.55 0.2 0.2
Cs, Ds: "s" for side notched

Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

8
Creep crack initiation time (ai=0,5mm)
GX12CrMoWVNbN9-1/2A, 550C, Ds60-specimen
1
10
100
1000
10000
Experiment Conservative crack initiation
curve
Mean crack initiation curve
C
r
e
e
p

c
r
a
c
k

i
n
i
t
i
a
t
i
o
n

t
i
m
e

ti
/

h

Figure 7: Creep crack initiation time of a component specimen (large sized Ds60-specimen)
Creep crack growth
GX12CrMoWVNbN9-1/2A, 550C, Ds60-specimen
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0 2000 4000 6000 8000 10000 12000
t / h

a

/

m
m
Experiment
Calculation (conservative curve)
Calculation (mean curve)

Figure 8: Creep crack growth of a component specimen (large sized Ds60-specimen)
0
5
10
15
20
25
10000 100000 1000000
C* max C* mittel
10000 100000 1000000

t (h)

Figure 9: Determination of creep crack growth for the nozzle corner crack (see Figure 1)
a (mm)
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

9
10
1
10
2
10
3
10
4
10
5
Creep crack initiation
(Ds60-specimens)
t
i Ds60
/t
i Cs25
1,5
t
i Ds60
/t
i Cs25
5
Cs25-specimens:
+)
a
0
/W = 0,55 (0,57)
+)
fatigue pre-cracked
Ds60-specimens:
a
0
/W = 0,20
Creep crack initiation
(Cs25-specimens)
K
I0
(MPa m
1/2
)
t
i
(h)



X12CrMoWVNbN10-1-1/1A
T = 600 C
a
i
= 0,5 mm

Figure 10: Creep crack initiation time of Cs25- and Ds60-specimens (a
i
= 0.5 mm)
depending on stress intensity factor K
I0
, forged steel X12, T=600C
10
1
10
2
10
3
10
4
10
5
Creep crack initiation
(Ds60 specimens)
t
i Ds60
/t
i Cs25
1,5
t
i Ds60
/t
i Cs25
7
Cs25-specimens:
+)
a
0
/W = 0,55 (0,57)
+)
fatigue pre-cracked
Ds60-specimens:
a
0
/W = 0,20
Creep crack initiation
(Cs25 specimens)
K
I0
(MPa m
1/2
)
t
i
(h)



GX12CrMoWVNbN10-1-1/2A
T = 600 C
a
i
= 0,5 mm

Figure 11: Creep crack initiation time of Cs25- and Ds60-specimens (a
i
= 0.5 mm)
depending on stress intensity factor K
I0
, cast steel GX12, T=600C
Creep-Fatigue in 9-12Cr Steels OMMI (Vol.3, Issue 2) August 2004

10
10
1
10
2
10
3
10
4
10
5
Scatterband
creep crack initiation
Cs25-specimens
t
H
= 0,3 h
t
H
= 3,0 h
f = 1/t
H
Cs25 Cs25
+)


+)
fatigue pre-cracked

C*
(N/mmh)
t
i
(h)


X12CrMoWVNbN10-1-1/1A
T = 600 C
a
i
= 0,5 mm

Figure 12: Creep-fatigue crack initiation time as a function of C* depending on hold time t
H

10
1
10
2
10
3
10
4
10
5
t
H
= 3,0 h
t
H
= 0,3 h
f = 1/t
H
Creep crack initiation
Cs25-specimens
Cs25 Cs25
+)


+)
fatigue pre-cracked

K
I0
(MPa m
1/2
)
t
i
(h)


X12CrMoWVNbN10-1-1/1A
T = 600 C
a
i
= 0,5 mm

Figure 13: Creep-fatigue crack initiation time as a function of K
I
depending on hold time t
H