电站9Cr-1Mo-V-Nb钢高温氧化机制及防护技术研究
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摘要
随着机组参数的提高,要求制造火力机组的材料必须具有更高的强度和更好的耐热性能。因此,解决金属材料的耐高温和耐高压问题是发展大机组的关键因素之一。9Cr-1Mo-V-Nb钢是美国上世纪七十年代研制开发的火力发电厂用热强钢,用作锅炉受热面小管时为T91,用作锅炉蒸汽管道、集热箱、再热器、蒸汽导管等大管道钢种是P91钢。该钢种具有较高的许用应力、持久强度、蠕变抗力、疲劳强度和热导率和良好的焊接性和较好的抗蚀性以及适中的价格。当今美、欧、日等先进国家的火力发电厂已普遍使用了T91和P91钢,并取得了良好的经济效益。我国于“十五”期间引进了该钢种,并进行了国产化研究与生产,10Cr9Mo1VNb钢就是T91,P91的国产化新钢种,但10Cr9Mo1VNb钢的研究和生产尚存在诸多问题,钢管质量与先进国家相比有较大差距。特别是T91钢的高温氧化是普遍存在的问题,为解决我国热强钢10Cr9Mo1VNb性能比先进国家有较大差距问题,本文开展了该钢的组织结构、常温和高温性能等的应用理论研究,进行了在空气和水蒸汽中的等温氧化,水蒸汽中循环氧化研究,详细研讨了该钢在高温氧化时的性能特征。并针对其氧化腐蚀规律,研究了其高温氧化防护技术,以期指导生产实际。
本文首先通过对P91钢的化学成分、力学性能、组织结构等方面的分析,深入研究了P91钢的强韧性机理、应能达到的性能指标和具备的微观组织形态,比较了P91的性能特点。并根据高温试验结果,建立了持久强度方程和外推曲线,为预测运行P91钢的剩余寿命奠定了基础。
本文系统研究了T91钢在空气介质、水蒸汽和氩气混合介质中的恒温氧化行为。研究了T91钢在空气中的高温恒温氧化行为,发现T91在空气气氛中氧化120小时,氧化膜仍很薄,说明它在空气中抗氧化能力较强。本文研究了T91钢在(Ar+10 vol.%H_2O)混合气氛中600℃、650℃和700℃下的恒温氧化行为。结果表明:恒温氧化10小时过程中,600℃下遵从抛物线规律;而在650℃和700℃下遵从分阶段抛物线规律,后一阶段的速度常数要高于前一阶段的速度常数。随温度升高,氧化速度明显增大。氧化激活能为157.2kJ/mol。T91钢氧化时形成了多层结构的氧化膜,从外到内依次为Fe_2O_3、Fe_3O_4和(Fe,Cr)_3O_4。同时钢基体也发生了内氧化,内氧化物为FeO和Cr_2O_3。只有在700℃下,无外层Fe_2O_3形成和内氧化发生。T91氧化后冷却至室温,氧化膜发生了开裂或局部剥落。最外层Fe_2O_3与次外层Fe_3O_4间存在很大裂隙,Fe_2O_3层容易剥落。根据上述结果建立了T91在含水蒸汽气氛中的氧化机制。
本文系统研究了T91钢在10%H_2O+90%Ar混合气氛中600℃、650℃和700℃下的循环氧化行为。结果表明:T91钢在在10%H_2O+90%Ar气氛中在600℃循环氧化290小时,氧化动力学分为明显的三个阶段,而在650℃和700℃下即使在氧化初期也出现较快的氧化速率。随温度升高,氧化速度明显增大。氧化过程中氢缺陷对加速氧化具有明显作用。在三个不同温度下,氧化膜存在明显的两层结构,外层为Fe_2O_3,内层为(Fe,Cr)_3O_4。与恒温氧化不同的是,在不同温度下循环氧化后样品表面均不同程度地出现了部分氧化产物的剥落区(标记为S),在700℃下甚至在剥落区都能观察到裂纹的存在。根据氧化膜的结构本文建立了一种降温过程中氧化膜热应力模型,通过计算表明:在氧化过程中内、外层氧化膜均受到较大的拉应力,且随循环氧化进行,拉应力缓慢降低。该模型解释了循环过程中氧化膜剥落的现象以及在实际生产启停过程中的氧化膜剥落现象。
为防止循环氧化过程中氧化膜的剥落,根据本文研究的氧化膜特性及剥落机理,设计了两种防止氧化膜剥落的方法,并分别进行了试验。第一种是采用热浸镀铝,第二种是涂覆稀土材料。
本文将热浸镀铝退火后T91钢样品在10%H_2O+90%Ar气氛中600℃、650℃和700℃下进行循环氧化后,采用XRD、SEM/EDS对氧化物成分、结构、形貌进行分析,结果发现:试样表面形成了Fe_2Al_5金属间化合物相,在Fe_2Al_5相下同时存在一层扩散层。在表面镀层中有贯穿Fe_2Al_5层的裂纹。镀层表现出良好的抗氧化性能,在循环氧化过程中,镀层内裂纹增加,并导致镀层剥落和退化。
本文研究了T91钢涂覆Y_2O_3样品在90%Ar+10%H_2O气氛中600℃、650℃和700℃下的循环氧化行为,并同时与空白试样进行了对比试验。结果表明:处理后试样的氧化速度明显低于空白样品的氧化速度,且在三个不同实验温度下涂覆Y_2O_3的样品的增重现象没有明显区别。涂覆纳米Y_2O_3样品氧化后表面生成了Fe_3O_4和Cr_2O_3,稀土元素对于表面形成Cr_2O_3具有促进作用,而Cr_2O_3的形成提高了T91钢在10%H_2O+90%Ar气氛中的抗氧化性和氧化膜的抗剥落性。
本文发现采用热浸镀铝和纳米稀土涂覆的方法均有效降低了T91在高温水蒸汽下的腐蚀速度,施加两种涂层后,在相同条件下氧化增重较空白样品的氧化增重低了1—2个数量级。在试验的条件下,未观察到纳米稀土涂覆材料的试样有氧化膜的剥落现象,说明其更具有良好的抗氧化性。
本文对应用越来越广泛的T/P91的性能进行了详细研究,而在水蒸汽中的循环氧化和针对氧化膜剥落防护技术鲜有报道。这种针对在运行过程中氧化膜的剥落防护技术,具有十分重要的应用价值。然而,热浸镀铝样品镀层有裂纹存在随氧化进行存在轻微剥落。实验条件下稀土更明显地提高了T91钢的抗氧化性能,由于管道内气相的冲刷作用可能导致涂覆层剥落而降低其防护效率,涂覆的氧化钇尚有待现场检测其防护效果。因此,应进一步结合现场实际运行情况,完善其防护工艺,更好地应用于生产实际。
With the development of the units having high temperature and pressure,a new type of material is needed.Therefore,the technology of developing the heat resistant material with having better performance has become an important problem of building large units.9Cr-1Mo-V-Nb(T91/P91)steel are heat resistant steels developed during 1970s in US for boiler components such as steam piping,steam head,reheater,etc in fossil power plants.The steels have higher performance in terms of allowable stress, rupture strength,creep-resistant ability,fatigue strength,and heat conductivity.The steels also have better weld ability and corrosion-resistant ability with a moderate price.Up to now,T91 and P91 have been widely used in fossil plants of the advanced countries and regions such as US,Europe and Japan with good economic benefits achieved.The steels were introduced in China during the 10th 5-year plan period,and the researches on its localization and the productions of the steels have since then been initiated.The 10Cr9Mo1VNb is a newly localized type of steel imitative of T91 and P91.But there have been many problems with 10Cr9Mo1VNb in its research and production.The quality of tube made of 10Cr9Mo1VNb is still substantially lower than that of tube made in advanced countries with as to be applied in power plant.
In order to fill the performance gap between 10Cr9Mo1VNb and T91/P91,this paper carries out investigations on theoretical understanding and practice concerning production process;tube quality and engineering applications of domestically produced T91 and P91 steel.The paper also conducts application researches on theories of its structure,strengthening mechanism,alloying mechanism.Creep rupture equation and extrapolation were developed based on the data conducted at three different temperatures,which can be used for life assessment of the operating tubes.
The thermostatic and cyclic oxidation were performed at three temperatures in air and mixed Ar and H_2O.
The thermostatic oxidation behavior of SA213T91(T91) steel in (Ar+10vol.%H_2O) and air atmosphere at 650℃was investigated.The oxidation behavior of T91 steel in(Ar+10vol.%H20) atmosphere at 600℃,650℃and 700℃was investigated.During oxidation for 10h the oxidation kinetics followed a parabolic law at 600℃,but two-stage parabolic law at 650℃and 700℃,in which the rate constant at the initial stage was higher than that at the second stage.With temperature up,the oxidation rate of T91 steel increased significantly.The oxidation activation energy was identified as 157.2 kJ/mol.The oxide scale with three-layer microstructure was composed of Fe_2O_3,Fe_3O_4 and(Fe,Cr)_3O_4 in the order from the top layer to the inner layer.Meanwhile the internal oxidation was also observed,the corresponding internal oxides were Cr_2O_3 and FeO.However,at 700℃,Fe_2O_3 neither outer layer nor internal oxides formed.The outer layer(Fe_2O_3) had a weak adhesion to the intermediate layer (Fe_3O_4),easily spalled during cooling from oxidation temperature to room temperature.The oxidation mechanism of T91 in(Ar+H_2O) atmosphere was discussed finally.
The cyclic oxidation behavior of T91 steel in 10%H_2O+90%Ar at 600℃,650℃and 700℃for various time was also studied.The experimental results indicated that a duplex oxide scale with an outer layer of Fe_2O_3 and an inner layer of mixed(Fe, Cr)_3O_4 formed on T91 steel during cyclic oxidation.In those test,the spallation of oxide scale was observed during cyclic oxidation of T91 steel at 600℃,650℃and 700℃,which indicated that stress generated in the oxide layer during cyclic oxidation. Some through cracks generated in both inner and outer oxide layers.Parts of oxide scales spalled from substrate during the cyclic oxidation.The oxidation mechanism of T91 steel in 10%H_2O+90%Ar was discussed.The thermal stress was evaluated in two oxide layers to illustrate the spallation of the oxide layer.The calculation results showed that a higher tensile stress in the oxide layer was formed at the early oxidation stage than at the later oxidation stage during heating.This tensile stress resulted in the formation of cracks in the oxide layer.
In order to preventing the scale spallated from the oxide layers,two methods were done in the paper,which were aluminide coating and Y_2O_3 coated.
An aluminide coating containing Fe_2Al_5 intermetallic was prepared on T91 steel by hot dip aluminizing.A diffusion layer containing Al existed beneath this coating during annealing.Some penetrated cracks were observed in the coating.The cyclic oxidation behavior of aluminide coated T91 steel was studied in 10%H_2O+90%Ar at 600℃、650℃and 700℃for various time.The observations showed that the coated sample exhibited much better oxidation resistance than that of bare sample oxidized under the sample conditions.AFM observation revealed that the growth of was dominated by Al diffusion outward.However,with temperature increasing,the oxidation rate was accelerated.During the cyclic oxidation,more cracks formed in the coating and part of coating spalled from sample surface,which resulted in degradation of coating.
The cyclic oxidation behavior of Y_2O_3 coated T91 steel was studied in 10%H_2O +90%Ar at 600℃,650℃and 700℃for 100 cycles.The research results indicated that after T91 steel coated by Y_2O_3 the oxidation rate was obviously lower than that of bare samples under the same oxidation conditions.Furthermore,Y_2O_3 coated sample exhibited approximate oxidation rate at 600℃,650℃and 700℃.For the coated sample surface the oxide phases on the sample surface was identified as Fe_3O_4 and Cr_2O_3 after oxidation.The yttrium promoted formation of Cr_2O_3 on the sample surface, which improved the oxidation resistance and spallation of oxide scale of T91 steel in in 10%H_2O+90%Ar on the sample surface under the test temperature.
本文首先通过对P91钢的化学成分、力学性能、组织结构等方面的分析,深入研究了P91钢的强韧性机理、应能达到的性能指标和具备的微观组织形态,比较了P91的性能特点。并根据高温试验结果,建立了持久强度方程和外推曲线,为预测运行P91钢的剩余寿命奠定了基础。
本文系统研究了T91钢在空气介质、水蒸汽和氩气混合介质中的恒温氧化行为。研究了T91钢在空气中的高温恒温氧化行为,发现T91在空气气氛中氧化120小时,氧化膜仍很薄,说明它在空气中抗氧化能力较强。本文研究了T91钢在(Ar+10 vol.%H_2O)混合气氛中600℃、650℃和700℃下的恒温氧化行为。结果表明:恒温氧化10小时过程中,600℃下遵从抛物线规律;而在650℃和700℃下遵从分阶段抛物线规律,后一阶段的速度常数要高于前一阶段的速度常数。随温度升高,氧化速度明显增大。氧化激活能为157.2kJ/mol。T91钢氧化时形成了多层结构的氧化膜,从外到内依次为Fe_2O_3、Fe_3O_4和(Fe,Cr)_3O_4。同时钢基体也发生了内氧化,内氧化物为FeO和Cr_2O_3。只有在700℃下,无外层Fe_2O_3形成和内氧化发生。T91氧化后冷却至室温,氧化膜发生了开裂或局部剥落。最外层Fe_2O_3与次外层Fe_3O_4间存在很大裂隙,Fe_2O_3层容易剥落。根据上述结果建立了T91在含水蒸汽气氛中的氧化机制。
本文系统研究了T91钢在10%H_2O+90%Ar混合气氛中600℃、650℃和700℃下的循环氧化行为。结果表明:T91钢在在10%H_2O+90%Ar气氛中在600℃循环氧化290小时,氧化动力学分为明显的三个阶段,而在650℃和700℃下即使在氧化初期也出现较快的氧化速率。随温度升高,氧化速度明显增大。氧化过程中氢缺陷对加速氧化具有明显作用。在三个不同温度下,氧化膜存在明显的两层结构,外层为Fe_2O_3,内层为(Fe,Cr)_3O_4。与恒温氧化不同的是,在不同温度下循环氧化后样品表面均不同程度地出现了部分氧化产物的剥落区(标记为S),在700℃下甚至在剥落区都能观察到裂纹的存在。根据氧化膜的结构本文建立了一种降温过程中氧化膜热应力模型,通过计算表明:在氧化过程中内、外层氧化膜均受到较大的拉应力,且随循环氧化进行,拉应力缓慢降低。该模型解释了循环过程中氧化膜剥落的现象以及在实际生产启停过程中的氧化膜剥落现象。
为防止循环氧化过程中氧化膜的剥落,根据本文研究的氧化膜特性及剥落机理,设计了两种防止氧化膜剥落的方法,并分别进行了试验。第一种是采用热浸镀铝,第二种是涂覆稀土材料。
本文将热浸镀铝退火后T91钢样品在10%H_2O+90%Ar气氛中600℃、650℃和700℃下进行循环氧化后,采用XRD、SEM/EDS对氧化物成分、结构、形貌进行分析,结果发现:试样表面形成了Fe_2Al_5金属间化合物相,在Fe_2Al_5相下同时存在一层扩散层。在表面镀层中有贯穿Fe_2Al_5层的裂纹。镀层表现出良好的抗氧化性能,在循环氧化过程中,镀层内裂纹增加,并导致镀层剥落和退化。
本文研究了T91钢涂覆Y_2O_3样品在90%Ar+10%H_2O气氛中600℃、650℃和700℃下的循环氧化行为,并同时与空白试样进行了对比试验。结果表明:处理后试样的氧化速度明显低于空白样品的氧化速度,且在三个不同实验温度下涂覆Y_2O_3的样品的增重现象没有明显区别。涂覆纳米Y_2O_3样品氧化后表面生成了Fe_3O_4和Cr_2O_3,稀土元素对于表面形成Cr_2O_3具有促进作用,而Cr_2O_3的形成提高了T91钢在10%H_2O+90%Ar气氛中的抗氧化性和氧化膜的抗剥落性。
本文发现采用热浸镀铝和纳米稀土涂覆的方法均有效降低了T91在高温水蒸汽下的腐蚀速度,施加两种涂层后,在相同条件下氧化增重较空白样品的氧化增重低了1—2个数量级。在试验的条件下,未观察到纳米稀土涂覆材料的试样有氧化膜的剥落现象,说明其更具有良好的抗氧化性。
本文对应用越来越广泛的T/P91的性能进行了详细研究,而在水蒸汽中的循环氧化和针对氧化膜剥落防护技术鲜有报道。这种针对在运行过程中氧化膜的剥落防护技术,具有十分重要的应用价值。然而,热浸镀铝样品镀层有裂纹存在随氧化进行存在轻微剥落。实验条件下稀土更明显地提高了T91钢的抗氧化性能,由于管道内气相的冲刷作用可能导致涂覆层剥落而降低其防护效率,涂覆的氧化钇尚有待现场检测其防护效果。因此,应进一步结合现场实际运行情况,完善其防护工艺,更好地应用于生产实际。
With the development of the units having high temperature and pressure,a new type of material is needed.Therefore,the technology of developing the heat resistant material with having better performance has become an important problem of building large units.9Cr-1Mo-V-Nb(T91/P91)steel are heat resistant steels developed during 1970s in US for boiler components such as steam piping,steam head,reheater,etc in fossil power plants.The steels have higher performance in terms of allowable stress, rupture strength,creep-resistant ability,fatigue strength,and heat conductivity.The steels also have better weld ability and corrosion-resistant ability with a moderate price.Up to now,T91 and P91 have been widely used in fossil plants of the advanced countries and regions such as US,Europe and Japan with good economic benefits achieved.The steels were introduced in China during the 10th 5-year plan period,and the researches on its localization and the productions of the steels have since then been initiated.The 10Cr9Mo1VNb is a newly localized type of steel imitative of T91 and P91.But there have been many problems with 10Cr9Mo1VNb in its research and production.The quality of tube made of 10Cr9Mo1VNb is still substantially lower than that of tube made in advanced countries with as to be applied in power plant.
In order to fill the performance gap between 10Cr9Mo1VNb and T91/P91,this paper carries out investigations on theoretical understanding and practice concerning production process;tube quality and engineering applications of domestically produced T91 and P91 steel.The paper also conducts application researches on theories of its structure,strengthening mechanism,alloying mechanism.Creep rupture equation and extrapolation were developed based on the data conducted at three different temperatures,which can be used for life assessment of the operating tubes.
The thermostatic and cyclic oxidation were performed at three temperatures in air and mixed Ar and H_2O.
The thermostatic oxidation behavior of SA213T91(T91) steel in (Ar+10vol.%H_2O) and air atmosphere at 650℃was investigated.The oxidation behavior of T91 steel in(Ar+10vol.%H20) atmosphere at 600℃,650℃and 700℃was investigated.During oxidation for 10h the oxidation kinetics followed a parabolic law at 600℃,but two-stage parabolic law at 650℃and 700℃,in which the rate constant at the initial stage was higher than that at the second stage.With temperature up,the oxidation rate of T91 steel increased significantly.The oxidation activation energy was identified as 157.2 kJ/mol.The oxide scale with three-layer microstructure was composed of Fe_2O_3,Fe_3O_4 and(Fe,Cr)_3O_4 in the order from the top layer to the inner layer.Meanwhile the internal oxidation was also observed,the corresponding internal oxides were Cr_2O_3 and FeO.However,at 700℃,Fe_2O_3 neither outer layer nor internal oxides formed.The outer layer(Fe_2O_3) had a weak adhesion to the intermediate layer (Fe_3O_4),easily spalled during cooling from oxidation temperature to room temperature.The oxidation mechanism of T91 in(Ar+H_2O) atmosphere was discussed finally.
The cyclic oxidation behavior of T91 steel in 10%H_2O+90%Ar at 600℃,650℃and 700℃for various time was also studied.The experimental results indicated that a duplex oxide scale with an outer layer of Fe_2O_3 and an inner layer of mixed(Fe, Cr)_3O_4 formed on T91 steel during cyclic oxidation.In those test,the spallation of oxide scale was observed during cyclic oxidation of T91 steel at 600℃,650℃and 700℃,which indicated that stress generated in the oxide layer during cyclic oxidation. Some through cracks generated in both inner and outer oxide layers.Parts of oxide scales spalled from substrate during the cyclic oxidation.The oxidation mechanism of T91 steel in 10%H_2O+90%Ar was discussed.The thermal stress was evaluated in two oxide layers to illustrate the spallation of the oxide layer.The calculation results showed that a higher tensile stress in the oxide layer was formed at the early oxidation stage than at the later oxidation stage during heating.This tensile stress resulted in the formation of cracks in the oxide layer.
In order to preventing the scale spallated from the oxide layers,two methods were done in the paper,which were aluminide coating and Y_2O_3 coated.
An aluminide coating containing Fe_2Al_5 intermetallic was prepared on T91 steel by hot dip aluminizing.A diffusion layer containing Al existed beneath this coating during annealing.Some penetrated cracks were observed in the coating.The cyclic oxidation behavior of aluminide coated T91 steel was studied in 10%H_2O+90%Ar at 600℃、650℃and 700℃for various time.The observations showed that the coated sample exhibited much better oxidation resistance than that of bare sample oxidized under the sample conditions.AFM observation revealed that the growth of was dominated by Al diffusion outward.However,with temperature increasing,the oxidation rate was accelerated.During the cyclic oxidation,more cracks formed in the coating and part of coating spalled from sample surface,which resulted in degradation of coating.
The cyclic oxidation behavior of Y_2O_3 coated T91 steel was studied in 10%H_2O +90%Ar at 600℃,650℃and 700℃for 100 cycles.The research results indicated that after T91 steel coated by Y_2O_3 the oxidation rate was obviously lower than that of bare samples under the same oxidation conditions.Furthermore,Y_2O_3 coated sample exhibited approximate oxidation rate at 600℃,650℃and 700℃.For the coated sample surface the oxide phases on the sample surface was identified as Fe_3O_4 and Cr_2O_3 after oxidation.The yttrium promoted formation of Cr_2O_3 on the sample surface, which improved the oxidation resistance and spallation of oxide scale of T91 steel in in 10%H_2O+90%Ar on the sample surface under the test temperature.
引文
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