![Page 1: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/1.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
1
Materials for Advanced Ultra-Supercritical Steam Service - Turbines
Phil Maziasz, Amit ShyamMaterials Science and Technology Division
Oak Ridge National Laboratory
2014 NETL Crosscutting Research Review Meeting, 19-23 May, 2014, Pittsburgh, PA
![Page 2: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/2.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Acknowledgements – Funding, U.S. Department of Energy – Office of Fossil Energy
DOE Headquarters/Germantown, MD – Regis Conrad DOE/NETL – Pittsburgh, PA – Vito Cedro
2
![Page 3: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/3.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Acknowledgements – Collaboration
Paul Jablonski, NETL/Albany (OR) Casting and Processing
3
![Page 4: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/4.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Increasing Steam Temperature and Pressure Increases Thermal Efficiency and Decreases Emissions for Advanced
UltraSuperCritical (A-USC) Steam Technology
“Least Regret” Strategy for CO2 Reduction (Viswanathan and Shingledecker, EPRI Conf., Santa Fe, NM, Aug. 2010)
![Page 5: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/5.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Compositions of Ni-based superalloys being considered for A-USC steam turbine application
Alloy Ni Cr Co Mo Nb Ti Al Mn Si C
NI 105 bal 14.85 20.0 5.0 - 1.1 4.7 0.5 0.5 0.15
HR 282 bal 19.5 10.0 8.5 - 2.1 1.5 0.15 0.15 0.07
IN 740 bal 25.0 20.0 0.5 1.5 1.5 1.3 0.3 0.3 0.03
Alloy 263
bal 20.0 20.0 5.8 - 2.1 0.35 0.5 0.35 0.07
![Page 6: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/6.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
A-USC Turbine Designs Need Ni-based Superalloys (rotors, blading, casing)
6
Wrought Ni-based superalloys (NI 105 and HR 282) have creep-strength needed for rotors and blading to last 250,000h
Consortium Phase 1Result
Cast Ni-based superalloys were needed for turbine casing
![Page 7: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/7.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Materials Selection for A-USC Steam Turbine Components - Summary
Blading – HR 282, NI 105 (wrought) Bolting – NI 105 (wrought) Rotors – HR 282 (wrought) Casing – HR 282, HR 263 (cast)
7
![Page 8: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/8.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Testing of Narrow-gap GTAWs of Cast HR 282 supplied by GE
18 cross-weld specimens have been machined
Stress-rupture creep testing is underway
![Page 9: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/9.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Welded HR 282 – Creep at 800C/200 MPa
0
200
400
600
800
1000
1200
1400
As‐welded As‐welded + aged Unwelded basemetal
As‐welded + SA +aged
Creep ‐rup
ture life (h
)
Post‐weld heat‐treatments
Creep of Welded cast HR 282
800C/200MPa
![Page 10: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/10.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Welded HR 282 – Creep at 750C/250 MPa
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
As‐welded As‐welded + aged unwelded baseline As‐welded + SA +aged
Creep ‐rup
ture life (h
)
Post‐weld heat‐treatments
750C/250MPa
750C/250MPa
![Page 11: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/11.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Welded HR 282 – Creep at 800C/200 MPa
As-welded
Welded + SA+ aged
![Page 12: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/12.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Fatigue Testing of Wrought HR 282 Alloy
A unique facility to provide high-temperature fatigue testing in steam was designed and assembled
Initial testing encountered some problems that had to be overcome
Preliminary results of steam and air testing of wrought HR 282 at 800oC are presented
12
![Page 13: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/13.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Steam Fatigue Testing Setup
Steam Generator(water chemistry is controlled)
Assembled Load Train at 800oC
Steam inlet
Thermocouplesand steam outlet
Extensometer portin furnace (closed)
Water cooledBellow (on both sides)
Inconel retort
![Page 14: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/14.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
More details of assembly
Bellows
Retort
Specimen with three TCs Top part of load train assembly
![Page 15: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/15.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Specimen design and machining details
• 45 degree cuts in at the specimen ends to reproduce alignment• Grooves outside gage section to tighten jamnut and specimen in pullrod (N155)
![Page 16: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/16.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Pullrod-specimen-jamnut assembly drawing
![Page 17: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/17.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Initial test details
Specimen with three TCs(before exposure)
Failed specimen of wrought Haynes 282T ~ 850oC; 100% steam; = 10 Hzmax = 55 ksi; R = ‐1 (expected fatigue limit is ~48 ksi in air in this condition)Nf = 184,659 cycles
Fatiguecrack
![Page 18: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/18.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Machine alignment
Machine aligned by instrumented specimen (pictured)Bending strain < 5% uniaxial strain as per ASTM standard
![Page 19: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/19.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Several iterations required + problems solved
• Thermocouple readings were off• Condensation in the bottom of the specimen• Temperature instability• Soaking time at temperature to be standardized• Last problem to be resolved
![Page 20: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/20.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
First good fatigue test in steam
![Page 21: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/21.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Hardness evolution with time at 800oC
• ~90% peak hardness reached after 1 hr soak so this soak time was used.
![Page 22: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/22.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Fatigue testing results to date
• No clear trend in terms of effect of steam environment• Relatively longer lifetimes are sub-surface crack initiation• Relate the fatigue lifetime variability to microstructural variability
![Page 23: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/23.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Optical microstructure – Haynes 282
![Page 24: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/24.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Optical microstructure – Haynes 282
![Page 25: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/25.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Fracture Surface Images50 ksi; R = -1
Nf (air) = 133,761 cycles Nf (100% steam) = 957,736 cycles
Air SF10Steam SF12
![Page 26: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/26.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Fracture Surface Images50 ksi; R = -1
Nf (air) = 133,761 cycles
Air SF10
![Page 27: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/27.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Fracture Surface Images50 ksi; R = -1
Nf (100% steam) = 957,736 cycles
Steam SF12, crack initiation site
![Page 28: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/28.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Fracture Surface Images52 ksi; R = -1
Nf (air) = 936,659 cycles Nf (100% steam) = 73,798 cycles
![Page 29: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/29.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
DOE/FE 2014 Project Review – FY14 Milestones
2014 project milestone – Analyze weldment data in terms of weld-reduction factors (Feb, 2014) - complete
2014 project milestone – Evaluate the effect of steam on fatigue behavior of HR 282 (June, 2014) – in progress
2014 project milestone – Prepare summary report on all test results to date on large cast heats (Sept. 2014) – in progress
29
![Page 30: Materials Testing for Advanced Ultrasupercritical System Turbines](https://reader031.vdocuments.net/reader031/viewer/2022020213/5870ca331a28ab1d758bfa3f/html5/thumbnails/30.jpg)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
30
Summary Cast HR 282 shows good weldability, and preliminary
creep-rupture properties of the weldment that are equivalent to the base-metal at 750-800oC with proper post-weld heat-treatment.
Unique and complex steam fatigue test facility was assembled and operated at ORNL
Preliminary HCF testing of wrought HR 282 at 800oC in steam and air shows no adverse effects of steam so far.
Microstructural effects on fracture site appear to most important effect of fatigue on HR 282 found to date