压力容器用钢在韧脆转变区的断裂韧性预测方法研究
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摘要
压力容器用铁素体钢在一定温度范围内存在韧脆转变的现象,成为压力容器,尤其是核反应堆压力容器结构完整性和安全性的潜在威胁。在这一温度区间,材料的断裂韧性表现出强烈的温度相关性以及高度分散性,使得其表述和数值确定相当困难。如何科学评价和预测材料断裂韧性的这一现象和规律,一直是学术界和工程界研究的热点和难点。本文基于主曲线法和Beremin解理断裂局部法,以国产核反应堆压力容器用钢A508-III以及我国常用压力容器用钢16MnR为研究对象,研究了压力容器用钢在韧脆转变区的断裂韧性预测方法。主要研究工作和成果如下：
(1)开展了ASTM E1921标准对国产典型压力容器钢16MnR和A508-III的适用性研究。按照ASTM E1921标准测得16MnR钢的参考温度T0为-63℃, A508-Ⅲ钢的T0为-61℃。实践证明ASTM E1921标准适用于这两种国产压力容器用钢。
(2)基于国产A508-III钢和16MnR钢,开展了小试样测试T0的试验研究。研究发现,即使严格按照E1921标准的程序,采用小试样进行T0测试,仍然可能得到错误的结果：与大尺寸试样的测试结果相比,T0测试值被过低估计了30-40多摄氏度。为了防止出现错误的T0测试结果,本文建议了4种审核小试样所测得的T0值有效性的辅助判断方法：(ⅰ)采用更大的Mlmit值；(ⅱ)检查断裂韧性数据的三参数Weibull分布斜率：(ⅲ)以Jp/Jc饥或CMODp/CMOD为指标评价KJc有效性；(ⅳ)用T0～TCVN经验关系判断T0值的有效性。
(3)采用从实际试验数据中随机抽样和从主曲线分布带中用Monte Carlo模拟随机抽样的方法,进行了Beremin模型参量的标定研究。研究表明,利用有限数量的试样通过Minami标定法无法确定Beremin模型参量m和σu。发现m与σu的变化存在规律,组成了一条该试样特有的m～σu曲线。
(4)提出了一个通过高低拘束不同试样m～σu曲线的交点确定Beremin模型参量的新标定方法。与已有的基于韧性换算模型(Toughness scaling model,TSM)的标定方法相比,该标定法计算量很小,不改变标定精度,可以直观地显示标定的收敛过程。
(5)利用主曲线描述的断裂韧性与温度的关系,在韧脆转变区不同温度下,采用Monte Carlo模拟抽样的方法标定了16MnR钢的Beremin模型参量,以此推测了该材料的Beremin参量随温度变化的规律,从而克服了有限试样数及Minami标定法导致的标定不确定性对分析参量与温度的关系所造成的影响。标定的结果表明,在所研究的温度范围内,m在下转变温度区随温度升高而减小,在下-中转变温度区保持与温度无关：σu随温度升高而增大。
(6)通过本文提出的m～σu曲线交点标定法和Ruggieri等人提出的基于TSM的标定法(RGD标定法)分别标定了16MnR钢和A508-Ⅲ钢的Beremin参量,采用Beremin韧性换算模型,将这两种钢的小试样断裂韧性值换算成高拘束大试样的结果,估算了用1T-SE(B)试样测试T0的预期值,解决了小试样T0测试值因拘束度不足而明显偏低的问题。
Ferritic steels used for construction of pressure vessels undergo a ductile-to-brittle transition (DBT) with decreasing temperature, which is a potential threat to the integrity and safety of pressure vessels, especially reactor pressure vessles. The fracture toughness of ferritic steels shows a strong temperature dependence on temperature and is highly scattered in the DBT region, which make it very diffcult to describe and measure the fracture toughness data. The scientific assessment and prediction of the ductile-to-brittle transion of materils pose great challenge to both the academic circle and the engineering circle. The main contents and conclusions of the thesis are as follows:
(1) The applicability of ASTM E1921to the domestic16MnR steel and the domestic A508-Ⅲ was investigated. The reference temperature To for16MnR was determined to be-63℃and the To value for A508-Ⅲ was-61℃in accordance with ASTM E1921. The applicability of ASTM E1921to the two types of steel was validated.
(2) The determination of the reference temperature To using small specimens of A508-Ⅲ and16MnR was carried out. The experiment results showed that small specimen may lead to non-consevative To estimate even when the test was performed according to E1921requirements. The reference temperatures calculated from the small specimens resulted in To estimates that were30℃to40℃below the estimates obtained from the larger specimens. To avoid the incorrect To estimate, four auxiliary methods for censoring To were suggested, including a more stringent Mlimit value, the evaluation of Weibull slope, the evaluation of the Kjc data validity in terms of Jp/Jc or CMODP/CMOD and the evaluation of To validity using the empirical correlation between To and TCVN from Charpy impact testing.
(3) Based on random sampling from experimental data and Monte Carlo simulation of data from the scatter band described by the Master Curve, it was proved that the calibration method proposed by Minami would result in large uncertainty in the calibrated Beremin's parametes, m and σu, when a finite number of data are available. It was found that m and σu vary regularly, and they constitute a unique curve for a specimen.
(4) A new calibration method was proposed to find Beremin's parmeters determined by the intersection of m～σn curves for high and low constraint specimens. Compared with the existing calibration method based on toughness scaling model (TSM), the new calibration method is characterized by low computational cost, the same accuracy and visual display of the calibration process.
(5) Monte Carlo simulation was employed to produce a large number of fracture toughness data randomly drawn from the scatter band described by the Master Curve to determine Beremin's parameters in the DBT region. In terms of16MnR steel, the results revealed that m decreases with temperature in the lower transition region and remains independent of temperature over the lower-to-mid transition. The changes in the scatter of macroscopic fracture toughness data and cleavage fracture mechanism are responsible for the temperature dependence of m. The Weibull stress scale parameter, σu, increases with temperature reflecting a rise in the microscale toughness.
(6) The Beremin's parameters for16MnR and A508-Ⅲ were calibrated using the calibration method based on the intersection of m-σu curves and the calibration method proposed by Ruggieri et al.(RGD method), respectively. After the fracture toughness data from small specimens were scaled to the results of1T-SE(B) by using Beremin's toughness scaling model, the To values were estimated. The underestimated T0b measured from small specimens, which exhibited loss of constraint, were corrected.
(1)开展了ASTM E1921标准对国产典型压力容器钢16MnR和A508-III的适用性研究。按照ASTM E1921标准测得16MnR钢的参考温度T0为-63℃, A508-Ⅲ钢的T0为-61℃。实践证明ASTM E1921标准适用于这两种国产压力容器用钢。
(2)基于国产A508-III钢和16MnR钢,开展了小试样测试T0的试验研究。研究发现,即使严格按照E1921标准的程序,采用小试样进行T0测试,仍然可能得到错误的结果：与大尺寸试样的测试结果相比,T0测试值被过低估计了30-40多摄氏度。为了防止出现错误的T0测试结果,本文建议了4种审核小试样所测得的T0值有效性的辅助判断方法：(ⅰ)采用更大的Mlmit值；(ⅱ)检查断裂韧性数据的三参数Weibull分布斜率：(ⅲ)以Jp/Jc饥或CMODp/CMOD为指标评价KJc有效性；(ⅳ)用T0～TCVN经验关系判断T0值的有效性。
(3)采用从实际试验数据中随机抽样和从主曲线分布带中用Monte Carlo模拟随机抽样的方法,进行了Beremin模型参量的标定研究。研究表明,利用有限数量的试样通过Minami标定法无法确定Beremin模型参量m和σu。发现m与σu的变化存在规律,组成了一条该试样特有的m～σu曲线。
(4)提出了一个通过高低拘束不同试样m～σu曲线的交点确定Beremin模型参量的新标定方法。与已有的基于韧性换算模型(Toughness scaling model,TSM)的标定方法相比,该标定法计算量很小,不改变标定精度,可以直观地显示标定的收敛过程。
(5)利用主曲线描述的断裂韧性与温度的关系,在韧脆转变区不同温度下,采用Monte Carlo模拟抽样的方法标定了16MnR钢的Beremin模型参量,以此推测了该材料的Beremin参量随温度变化的规律,从而克服了有限试样数及Minami标定法导致的标定不确定性对分析参量与温度的关系所造成的影响。标定的结果表明,在所研究的温度范围内,m在下转变温度区随温度升高而减小,在下-中转变温度区保持与温度无关：σu随温度升高而增大。
(6)通过本文提出的m～σu曲线交点标定法和Ruggieri等人提出的基于TSM的标定法(RGD标定法)分别标定了16MnR钢和A508-Ⅲ钢的Beremin参量,采用Beremin韧性换算模型,将这两种钢的小试样断裂韧性值换算成高拘束大试样的结果,估算了用1T-SE(B)试样测试T0的预期值,解决了小试样T0测试值因拘束度不足而明显偏低的问题。
Ferritic steels used for construction of pressure vessels undergo a ductile-to-brittle transition (DBT) with decreasing temperature, which is a potential threat to the integrity and safety of pressure vessels, especially reactor pressure vessles. The fracture toughness of ferritic steels shows a strong temperature dependence on temperature and is highly scattered in the DBT region, which make it very diffcult to describe and measure the fracture toughness data. The scientific assessment and prediction of the ductile-to-brittle transion of materils pose great challenge to both the academic circle and the engineering circle. The main contents and conclusions of the thesis are as follows:
(1) The applicability of ASTM E1921to the domestic16MnR steel and the domestic A508-Ⅲ was investigated. The reference temperature To for16MnR was determined to be-63℃and the To value for A508-Ⅲ was-61℃in accordance with ASTM E1921. The applicability of ASTM E1921to the two types of steel was validated.
(2) The determination of the reference temperature To using small specimens of A508-Ⅲ and16MnR was carried out. The experiment results showed that small specimen may lead to non-consevative To estimate even when the test was performed according to E1921requirements. The reference temperatures calculated from the small specimens resulted in To estimates that were30℃to40℃below the estimates obtained from the larger specimens. To avoid the incorrect To estimate, four auxiliary methods for censoring To were suggested, including a more stringent Mlimit value, the evaluation of Weibull slope, the evaluation of the Kjc data validity in terms of Jp/Jc or CMODP/CMOD and the evaluation of To validity using the empirical correlation between To and TCVN from Charpy impact testing.
(3) Based on random sampling from experimental data and Monte Carlo simulation of data from the scatter band described by the Master Curve, it was proved that the calibration method proposed by Minami would result in large uncertainty in the calibrated Beremin's parametes, m and σu, when a finite number of data are available. It was found that m and σu vary regularly, and they constitute a unique curve for a specimen.
(4) A new calibration method was proposed to find Beremin's parmeters determined by the intersection of m～σn curves for high and low constraint specimens. Compared with the existing calibration method based on toughness scaling model (TSM), the new calibration method is characterized by low computational cost, the same accuracy and visual display of the calibration process.
(5) Monte Carlo simulation was employed to produce a large number of fracture toughness data randomly drawn from the scatter band described by the Master Curve to determine Beremin's parameters in the DBT region. In terms of16MnR steel, the results revealed that m decreases with temperature in the lower transition region and remains independent of temperature over the lower-to-mid transition. The changes in the scatter of macroscopic fracture toughness data and cleavage fracture mechanism are responsible for the temperature dependence of m. The Weibull stress scale parameter, σu, increases with temperature reflecting a rise in the microscale toughness.
(6) The Beremin's parameters for16MnR and A508-Ⅲ were calibrated using the calibration method based on the intersection of m-σu curves and the calibration method proposed by Ruggieri et al.(RGD method), respectively. After the fracture toughness data from small specimens were scaled to the results of1T-SE(B) by using Beremin's toughness scaling model, the To values were estimated. The underestimated T0b measured from small specimens, which exhibited loss of constraint, were corrected.
引文
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