P92钢焊接接头IV型蠕变开裂机理及预测方法研究
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摘要
超超临界发电机组主蒸汽管道采用P92钢制造,其焊接接头的高温蠕变性能是薄弱环节之一。本文针对P92钢焊接接头中最危险的IV型蠕变开裂,对其开裂机理及蠕变损伤的演化过程及数值计算预测技术进行了深入研究。
本文对P92钢焊接接头进行了650℃和70MPa下的蠕变试验,经7000多小时的蠕变试验后,发生典型的IV型蠕变开裂,并通过显微组织分析和有限元方法分析了IV型开裂机理。
显微组织分析表明,P92钢焊接接头的IV型蠕变开裂过程即为细晶区的蠕变损伤过程。在焊接过程中,原先母材中粗大奥氏体晶界上的碳化物没有完全溶解,而是在焊接后形成的细晶区的晶界上析出。在高温蠕变中,细晶区中原来起强化作用的碳化物减少,而晶界上的碳化物长大及在晶界上生成新的粗大碳化物,成为蠕变空穴的形核源,导致细晶区的蠕变性能降低。当晶界上的蠕变空穴长大、聚合及连接后,发生晶界分离,随着分离的晶界不断增加,在原先的奥氏体晶界上形成微裂纹,直至试样发生断裂。
采用热处理法制备了P92钢焊接粗晶区和细晶区的模拟组织,并与焊逢金属和母材组织一起,通过单轴蠕变试验获得了接头各微区的蠕变曲线及蠕变参数,建立了描述接头各微区蠕变损伤的改进的K-R方程,并自行编写了具有高计算精度的、与ABAQUS软件接口的用户材料子程序UMAT,实现了对P92钢焊接接头的蠕变损伤的有限元计算。
有限元分析结果表明,除了试验应力和细晶区的低蠕变强度,IV型蠕变开裂还与应力再分布和应力三轴度有关。应力再分布对IV型开裂起到一定的阻碍作用,这是因为应力再分布使得细晶区承受的拉应力降低,而与细晶区临近的粗晶区和母材中的拉应力增加。
另外,由于低蠕变强度的细晶区被夹在高蠕变强度的粗晶区(焊缝金属)和母材之间,接头在承受拉伸载荷下,会引起细晶区的应力三轴度高于与其临近的粗晶区和母材。高应力三轴度可促进细晶区内蠕变空穴的萌生和长大,从而促进细晶区蠕变损伤的更快发展,而试样中心处较高的应力三轴度也使得试样中心处先出现蠕变损伤,并从试样中心向外表面发展,最终发生蠕变断裂。
根据对IV型蠕变开裂机理的研究,提出在焊接前对P92钢管进行多次短时间的正火热处理,尽可能溶解母材奥氏体晶界上的碳化物,可在一定程度上抑制P92钢焊接接头IV型开裂的倾向。
The main steam tubes of ultra supercritical fossil-fired power plants are usually produced by P92 steel, and the high-temperature creep properties of the welded joints is one of the weak links. In this paper, the most dangerous cracking type-Type IV cracking of P92 steel welded joints was studied, involving the cracking mechanism, the evolution of creep damage and the numerical calculation prediction techniques.
The various time creep test for welded joints of P92 steel had been conducted at 650℃under 70 MPa. When the total creep time reached to more than 7000 h, the Type IV cracking occurred. Then the Type IV cracking mechanism of P92 steel welded joint was investigated through the microstructure analysis and FEM analysis, respectively.
The microstructure analysis indicates that the Type IV cracking process essentially is the creep damage evolution process of the fine-grain HAZ in the welded joint. The carbides which were located at the coarse austenite grain boundary of the original base metal, were not completely dissolved during the welding process, and were precipitated on the grain boundaries of FGHAZ after the welding. In the creep, the carbides will grow up and new coarse carbides will form in the grain boundaries, and may become the nucleation site of the creep voids, so the coarse carbides lead to the decline of the FGHAZ creep strength. As the creep voids growing, they will coalesce together and connect each other, and the grain boundaries will be separated from the substrates. As the separated grain boundaries increase, the micro crack will form on the original austenite boundaries, and lead to the final fracture of the welded joint.
The creep specimens of the simulated FGHAZ and CGHAZ, which were prepared by heat treatment method, together with the weld metal specimens and base metal specimens, were tested in the uniaxial creep condition. The creep curves and creep parameters of the different zones of the welded joints were achieved and the modified K-R creep damage equations of the different micro zones were constructed. Then, the user material subroutine in ABAQUS-UMAT coupled with modified K-R damage equations was complied to calculate the creep damage in the P92 steel welded joint with a high accuracy.
The FEM analysis results showed that Type IV cracking was related to the stress redistribution and the stress triaxiality in the welded joints, beside the tested stress level and the low creep strength of the FGHAZ. The stress redistribution could suppress the Type IV cracking, because it made the tensile stress decrease in the FGHAZ and made the tensile stress increase in the CGHAZ and base metal.
In addition, the FGHAZ with low creep strength was located between the CGHAZ and base metal with high creep strength, so that the stress triaxiality of FGHAZ was higher than that of CGHAZ and that of base metal during the stress redistribution. The higher stress triaxiality could promote the initiation and growth of creep voids in FGHAZ, and accelerates of creep damage in FGHAZ. The FEM results also showed that the inner elements of welded joints specimen occurred firstly, and developed to the elements of outer surface. This can be explained that the stress triaxiality of the inner of the welded joint is higher than that of the outer surface.
According to the analyses of Type IV creep cracking mechanism, adding a suitable number of normalizing treatments on the P92 steel before welding ,which can dissolve the carbides in the austenitic grain boundaries as many as possible, is thought to be a better choice to suppress the descend of Type IV cracking in the welded joint.
本文对P92钢焊接接头进行了650℃和70MPa下的蠕变试验,经7000多小时的蠕变试验后,发生典型的IV型蠕变开裂,并通过显微组织分析和有限元方法分析了IV型开裂机理。
显微组织分析表明,P92钢焊接接头的IV型蠕变开裂过程即为细晶区的蠕变损伤过程。在焊接过程中,原先母材中粗大奥氏体晶界上的碳化物没有完全溶解,而是在焊接后形成的细晶区的晶界上析出。在高温蠕变中,细晶区中原来起强化作用的碳化物减少,而晶界上的碳化物长大及在晶界上生成新的粗大碳化物,成为蠕变空穴的形核源,导致细晶区的蠕变性能降低。当晶界上的蠕变空穴长大、聚合及连接后,发生晶界分离,随着分离的晶界不断增加,在原先的奥氏体晶界上形成微裂纹,直至试样发生断裂。
采用热处理法制备了P92钢焊接粗晶区和细晶区的模拟组织,并与焊逢金属和母材组织一起,通过单轴蠕变试验获得了接头各微区的蠕变曲线及蠕变参数,建立了描述接头各微区蠕变损伤的改进的K-R方程,并自行编写了具有高计算精度的、与ABAQUS软件接口的用户材料子程序UMAT,实现了对P92钢焊接接头的蠕变损伤的有限元计算。
有限元分析结果表明,除了试验应力和细晶区的低蠕变强度,IV型蠕变开裂还与应力再分布和应力三轴度有关。应力再分布对IV型开裂起到一定的阻碍作用,这是因为应力再分布使得细晶区承受的拉应力降低,而与细晶区临近的粗晶区和母材中的拉应力增加。
另外,由于低蠕变强度的细晶区被夹在高蠕变强度的粗晶区(焊缝金属)和母材之间,接头在承受拉伸载荷下,会引起细晶区的应力三轴度高于与其临近的粗晶区和母材。高应力三轴度可促进细晶区内蠕变空穴的萌生和长大,从而促进细晶区蠕变损伤的更快发展,而试样中心处较高的应力三轴度也使得试样中心处先出现蠕变损伤,并从试样中心向外表面发展,最终发生蠕变断裂。
根据对IV型蠕变开裂机理的研究,提出在焊接前对P92钢管进行多次短时间的正火热处理,尽可能溶解母材奥氏体晶界上的碳化物,可在一定程度上抑制P92钢焊接接头IV型开裂的倾向。
The main steam tubes of ultra supercritical fossil-fired power plants are usually produced by P92 steel, and the high-temperature creep properties of the welded joints is one of the weak links. In this paper, the most dangerous cracking type-Type IV cracking of P92 steel welded joints was studied, involving the cracking mechanism, the evolution of creep damage and the numerical calculation prediction techniques.
The various time creep test for welded joints of P92 steel had been conducted at 650℃under 70 MPa. When the total creep time reached to more than 7000 h, the Type IV cracking occurred. Then the Type IV cracking mechanism of P92 steel welded joint was investigated through the microstructure analysis and FEM analysis, respectively.
The microstructure analysis indicates that the Type IV cracking process essentially is the creep damage evolution process of the fine-grain HAZ in the welded joint. The carbides which were located at the coarse austenite grain boundary of the original base metal, were not completely dissolved during the welding process, and were precipitated on the grain boundaries of FGHAZ after the welding. In the creep, the carbides will grow up and new coarse carbides will form in the grain boundaries, and may become the nucleation site of the creep voids, so the coarse carbides lead to the decline of the FGHAZ creep strength. As the creep voids growing, they will coalesce together and connect each other, and the grain boundaries will be separated from the substrates. As the separated grain boundaries increase, the micro crack will form on the original austenite boundaries, and lead to the final fracture of the welded joint.
The creep specimens of the simulated FGHAZ and CGHAZ, which were prepared by heat treatment method, together with the weld metal specimens and base metal specimens, were tested in the uniaxial creep condition. The creep curves and creep parameters of the different zones of the welded joints were achieved and the modified K-R creep damage equations of the different micro zones were constructed. Then, the user material subroutine in ABAQUS-UMAT coupled with modified K-R damage equations was complied to calculate the creep damage in the P92 steel welded joint with a high accuracy.
The FEM analysis results showed that Type IV cracking was related to the stress redistribution and the stress triaxiality in the welded joints, beside the tested stress level and the low creep strength of the FGHAZ. The stress redistribution could suppress the Type IV cracking, because it made the tensile stress decrease in the FGHAZ and made the tensile stress increase in the CGHAZ and base metal.
In addition, the FGHAZ with low creep strength was located between the CGHAZ and base metal with high creep strength, so that the stress triaxiality of FGHAZ was higher than that of CGHAZ and that of base metal during the stress redistribution. The higher stress triaxiality could promote the initiation and growth of creep voids in FGHAZ, and accelerates of creep damage in FGHAZ. The FEM results also showed that the inner elements of welded joints specimen occurred firstly, and developed to the elements of outer surface. This can be explained that the stress triaxiality of the inner of the welded joint is higher than that of the outer surface.
According to the analyses of Type IV creep cracking mechanism, adding a suitable number of normalizing treatments on the P92 steel before welding ,which can dissolve the carbides in the austenitic grain boundaries as many as possible, is thought to be a better choice to suppress the descend of Type IV cracking in the welded joint.
引文
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