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doi:10.1520/JAI103712
Available online at www.astm.org/JAI
Introduction
ASTM E2714-09 [1] covers the determination of mechanical properties pertaining to creep-fatigue crack formation in nominally homogeneous materials by
the use of test specimens subjected to uniaxial forces under isothermal
Manuscript received December 22, 2010; accepted for publication March 3, 2011;
published online April 2011.
1
Dept. of Mechanical Engineering, Univ. of Arkansas, Fayetteville, AR 72701.
2
Dept. of Mechanical Engineering, Univ. of Arkansas, Fayetteville, AR 72701
(Corresponding author), e-mail: asaxena@uark.edu
3
EPRI, Charlotte, NC 28262.
Cite as: Kalyanasundaram, V., Saxena, A., Narasimhachary, S. and Dogan, B., ASTM
Round-Robin on Creep-Fatigue and Creep Behavior of P91 Steel, J. ASTM Intl., Vol. 8,
No. 4. doi:10.1520/JAI103712.
C 2011 by ASTM International, 100 Barr Harbor Drive, PO Box C700, West
Copyright V
Conshohocken, PA 19428-2959.
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23
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conditions. It concerns creep-fatigue testing at strain rates and/or cycles involving sufciently long hold times to induce creep deformation (and oxidation)
during cyclic deformation where cycles to crack formation are affected by
creep.
This test method is applicable to the determination of deformation and
crack formation or nucleation properties as a consequence of either constantamplitude strain-controlled tests or constant-amplitude force-controlled tests
with hold times. It is primarily concerned with the testing of round bar specimens subjected to uniaxial loading in either force or strain control, wherein the
latter is recommended. As a result of this round-robin, future improvements
planned for this standard include, but are not limited to, a more denitive precision and bias statement.
A total of 16 participants from laboratories all over the world are conducting tests under a coordinated set of test conditions. The primary objective of the
round-robin is to conduct creep-fatigue tests to characterize the number of
cycles for crack formation while using the procedures specied in the standard
to assess variability in the results. The list of participants, their afliation, and
the planned set of tests for each of them is provided in Table 1.
Test Material
The candidate materials considered for the round-robin were from a wide variety of materials that are used in high temperature applications and included gas
turbine materials for aircraft and land-based engines, fossil power plants, and
nuclear reactor materials. Other considerations included material availability in
sufcient quantities, offers of sponsorship for material and machining costs,
and the interest level in testing the material among the participating volunteers.
The test material selected is ASTM Grade P91 steel (donated by the Electric
Power Research Institute (EPRI), Charlotte) that has a creep rupture strength
of 94 MPa at 600 C for a life of 105 h. The nominal chemical composition of P91
steel in wt % is given in Table 2 [2]. There are two other round-robins with similar objectives that are under way. The Idaho National Laboratory is conducting
a separate round-robin on IN617 (a nickel-based superalloy) and the Japan Society for Promotion of Science is conducting one on ASTM Grade P92 material.
While these are parallel independent studies, an effort is planned to integrate
the ndings from all the studies at a later date.
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Si
0.31
0.11
0.45
Mn
2
2
2
2
2
2
2
2
60.75 %
2
2
2
2
2
2
2
2
4
60.5 %/10
min Hold
0.011
P
0.009
60.75 %/10
min Hold
0.19
Ni
8.22
Cr
0.94
Mo
0.005
As
0.21
0.07
Nb
0.006
Al
0.16
Cu
0.039
2
4
0.001
Bal.
Fe
60.5 %/30
min Hold
Sb, Sn
2
2
2
2
2
2
2
2
Conduct creep deformation and rupture testing and metallography
and TEM of the test material
2
2
2
60.5 %
60.25 %
StrainAmplitude %!
Participants
;
TABLE 1List of participants and test matrix for the ongoing ASTM round-robin (Numbers indicate the total number of tests planned under
those conditions).
FIG. 1(a) P91 pipe section used for the ASTM round-robin testing; (b) cross-sectional view of section 2 of the pipe section; (c)
machining layout for subsection 2-1 (Material courtesy of EPRI).
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FIG. 2(a) Creep-fatigue and (b) creep specimen layout used in the ASTM round-robin (all dimensions are in inches).
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FIG. 3(a) Optical micrograph of P91 steel microstructure with the inset showing inclusions and (b) shows a schematic of the
microstructure 9.
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TABLE 3Tensile test results of P91 steel at room and high temperature (625 C).
Test Temperature
C= F
24/75
625/1157
Elongation
(%)
532.6/77.2
325.1/47.1
708.4/102.7
343.7/49.8
26
33
listed in Table 3 and were found to be comparable to those published in the literature for P91 steels.
Creep tests were performed on smooth round specimens with a gage length
and diameter of 25 and 5 mm, respectively, which were designed as per the
ASTM E139 standard [8] [see Fig. 2(b)]. All tests were carried out at 625 C (898 K).
Creep tests were carried out under uniaxial static (constant stress and temperature) loading conditions in a lab-controlled atmosphere (2062 C and 50 % relative
humidity). The external static load was applied using dead weights and a calibrated
LVDT with a repeatability of 0:1 lm was employed to measure elongation during
the tests. The test temperature was monitored continuously during the entire span
of the tests using two K-type thermocouples wound mechanically at the top and
bottom ends of the specimen gage length. The temperature difference between the
top and bottom thermocouples during any test was continuously monitored and
found to be within the allowable limits of 62 C of the test temperature.
The LarsonMiller parameter PLM is used as a predictive parameter to
evaluate the stress level required for a given rupture time [10] and is denoted
analytically as
PLM Tk CLM logtr =1000
(1)
where:
Tk test temperature (K),
tr creep rupture time (h), and
CLM constant (30 for P91 steel).
The PLM plotted against the applied engineering stress (external static load
divided by the initial cross-sectional area of the specimen) r in MPa is used to
obtain the value of r for a given tr . For this round-robin, the test matrix was
designed such that tr ranges from 5000 to 150 h and the corresponding stress
levels range from 102 to 152 MPa (see Fig. 4). The data from the tests conducted
as part of this program are plotted with the data from the literature [11] in Fig.
4 and were found to lie perfectly within the trends of the literature data, thus
once again conrming that the test material behavior is within the limits of typical P91 steels.
The creep deformation mechanism of P91 steels can be dominated depending on stress and temperature, by cross-slip and dislocation climb > 70 MPa,
and by grain boundary diffusion < 70 MPa [12]. It has been found by
others that for martensitic steels, the metallurgical changes are of vital
importance as they strongly affect creep resistance properties leading to loss in
creep rupture strength [13]. From a microstructural perspective, it has been
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FIG. 4Larson Miller parameter plot from Ref 11, overlaid with data from the current
round-robin tests at 625 C.
observed that the M23 C6 precipitates in P91 link up by rapid directional coarsening during the primary creep regime. The resistance to creep deformation by
hindering of dislocation motion is increased by the evolution of this microstructure during the nal stages of primary creep and during the entire secondary
creep regime [14].
Creep strain versus time curves exhibited very short primary ( 10 % of tr )
creep followed by secondary or steady-state and substantial tertiary creep stages
under the tested conditions (see Fig. 5). Because of dynamic creep recovery
due to subgrain growth and dislocation migration/annihilation in grain
sub-boundaries, the primary creep strain rate starts to decrease until it reaches
a plateau at the onset of secondary or steady-state creep. The secondary creep
regime represents a dynamic equilibrium between work hardening and creep
recovery processes, wherein a balance between generation of new dislocations
and annihilation of existing dislocations is achieved [15]. The hindrance to dislocation motion due to the evolving precipitates mentioned above must also be
part of the overall dynamic equilibrium during secondary creep stage. The minimum creep rate _e ss as observed in the secondary creep regime is linearly t
using Nortons power law _ ss Arn (where A and n are material constants) and
the power law exponent n and constant A are found to be 8 and
9:5 1021 , respectively (see Table 4).
The onset of tertiary creep is characterized by accelerating creep rates as a
result of a combination of the following reasons [16]:
(1) increasing stress experienced in localized region(s) of the material due
to necking phenomenon
(2) increasing creep strain accumulation that leads to cavity formation and
growth and consequent damage that develops in the form of creep cavities over time
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FIG. 5Creep rupture (experimental versus modeled) curves for the completed ASTM round-robin tests of P91 steel at 625 C.
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TABLE 4Steady-state creep rate as a function of stress for P91 test material at 625 C.
Applied Stress
(MPa)
101.5
130.0
136.8
138.3
142.7
151.5
Steady-State Creep
Rate h1
0.000 35
0.001 66
0.003 81
0.005 23
0.007 79
0.007 48
(3) microstructural changes that are not associated with the accumulated
damage
The creep rupture ductility for P91 steel is high with the nal longitudinal
elongation varying from 1619 %. It can also be observed from Fig. 5 that the
creep strains associated with the primary and the secondary creep regimes are
relatively smaller than those associated with the tertiary creep regime, especially at the higher stress levels. Localized necking occurs at times past 95 %
of the creep rupture time (i.e., tr ) when macro-cracking also appears and contributes further to rupture elongation. Similar such observations have been
noted in other studies for this class of steels [9,12,13].
Optical microscopic analysis of ruptured creep specimens showed that the
cracking mode during creep rupture is a predominantly transgranular (ductile)
fracture with an array of microvoids growing through grains along crystallographic planes towards the nal rupture location [see Fig. 6(a)]. It is possible
that such a failure mode is due to plastic deformation at high stresses typically
used in accelerated laboratory testing. It is further noted that these arrays were
found most commonly near material inclusions [precipitates and/or secondary
phases, see Fig. 6(b)].
FIG. 6Transgranular (ductile) fracture mode as observed in P91 steel (a) before and
(b) after etching with Nital (3 % nitric acid in methanol) solution (Test condition:
151.5 MPa, 625 C).
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(2)
where:
fs
p
p
p
b
log1 C logru C ; fj logru C
logtr
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response thereafter. We also know that the reduction in area varies signicantly
based on the necking characteristics. Hence, the engineering creep strain at
rupture (t at time t tr ) is taken to be the measured uniform strain at rupture,
ru (i.e., strain generated in the specimens gage length before the onset of
necking in a localized region). This strain can be empirically obtained by evaluating the reduction in area Ared in the specimen gage length in regions away
from the neck. Rather than using the conventional ductility equation for Ared ,
an analytical form as shown in Eq 3 is employed in this work. As shown in
Fig. 7, the diameter of the specimen at locations 1, 2, and 3 is measured and
averaged to obtain dunif and this value is used to compute Aunif :
Ared
Aorig Aunif
Aorig
(3)
where:
Aorig original cross-sectional area in the specimen gage length and
Aunif uniform cross-sectional area obtained by using dunif (the average of
diameters in regions away from the neck).
Minimizing human measurement errors and the effect of complex strain
proles across the specimen gage length were the primary reasons for using the
average value of dunif rather than using a single diameter value in the
unnecked region. The choice of position of locations to compute dunif does not
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TABLE 5Modied LCSP model tting constants for P91 steel at 625 C.
Parameter
Value
0.27
1.65
9.15
2553.74
6.8
b
p0
p1
p2
C
Creep-Fatigue Tests
The creep-fatigue round-robin test matrix has been designed to address precision in the results obtained from tests when utilizing the procedure outlined in
the new standard E2714-09. More specically, the objective is to quantify intraand inter-laboratory variability in the creep-fatigue data. It is anticipated that
the standard will be revised as warranted by the results of the round-robin. For
example, questions such as what percentage drop in the force provides the most
consistent measure of the number of fatigue cycles for crack formation are
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FIG. 8Predicted creep strain rate by modied LCSP model for P91 steel as compared with that of experimental values for two different test conditions at 625 C.
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FIG. 9Pilot tests results from creep-fatigue testing of P91 steel, where Na is the number of cycles to failure. Data courtesy of Dr. Stuart Holdsworth of EMPA, Switzerland
and Dr. Yukio Takahashi of CRIEPI, Japan.
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Acknowledgments
The writers would like to acknowledge the technical assistance offered by Jeff
Mincy, University of Arkansas and Jeff Metz, Struers in metallographic
specimen preparation and related work. The data offered by NIRM, EMPA, and
CRIEPI (used in Fig. 9) are also highly appreciated.
References
ASTM E2714-09, Standard Test Method for Creep-Fatigue Testing, Annual Book
of ASTM Standards, Vol. 03.01, ASTM International, West Conshohocken, PA.
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[3]
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[4]
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