The IMPACT Project - Development of

MARBN Steel for Next Generaton Steam Plant

Ne! Materal" Semnar# I$M%# &on'on# (%-() Ma* (+,%-
Authors
Dav' Allen . /-$N Ne! B0l' 1 Technolo2*
Craig Degnan - E.ON New Build & Technology
Hailiang Du, Rod anstone - Alsto!
"aul #oody, "eter Barnard - Doosan "ower
$te%e Ro&erts - 'oodwin $teel Castings
Ryan #aclachlan, "ro(. Rachel Tho!son ) *ough&orough +ni%ersity
,
-#"ACT ) in outline
+. 'o%ern!ent /T$B0 1art-(unded industry-led colla&orati%e 1ro2ect
3 years ) ,454 to end ,456 Budget 75.8#
De%elo1!ent o( ad%anced welded #ARBN steels (or +$C 1ower 1lant
-!1ro%ed design (or welded co!1onents to reduce 1re!ature crac9ing
-!1ro%ed strain and !aterials !onitoring to allow high te!1 o1eration
$teel 1roduct ) $ha1ed casting, ingot (or (orging, tu&e !achining
De!onstration 1lant co!1onent ) welded &oiler tu&e insert on 1lant
-nteraction with +. :$u1ergen; /uni%ersity led0 1artnershi1
< Colla&orati%e interchange with ongoing CO$T = .##--N 1rogra!!e
6
-#"ACT - organisations
Partner"
E.ON New Build & Technology, Ratcli((e /Nottingha!0, +. ) 1lant user
Doosan "ower, Ren(rew /'lasgow0, +. ) &oilers = welding
Alsto!, Rug&y, +. ) tur&ine and 1ower 1lant technology
'oodwin $teel Castings, $to9e-on-Trent, +. ) cast !aterials su11lier
National "hysical *a&oratory, Teddington, +. ) !onitoring technology
*ough&orough +ni%., +. ) !icrostructural characterisation and !odelling
A""ocate"
Tata /Corus0, Rotherha!, +. ) steel de%elo1!ent ad%ice, su11ly
3
-#"ACT ) the 1eo1le
Partner"
E.ON ) Craig Degnan /"ro2ect #anager0, Da%id Allen /"ro2ect *eader0
Doosan ) "eter Barnard, "aul #oody
Alsto! +. ) Hailiang Du, Rod anstone
'oodwin ) $te%e Ro&erts, $te%e Bir9s
N"* ) >erry *ord, Bryan Roe&uc9
*+ ) "ro( Rachel Tho!son, Ryan #aclachlan, *etian *i, #ar9 >e1son
A""ocate"
Tata +. ) "eter #orris, Richard ?illia!s, "hili1 Clar9e
T$B contract #onitoring O((icer ) >on Tenner
@
-#"ACT ) the 1ro2ect roles
Partner"
< E.ON ) "ro2ect 1lanning, !anage!ent, testing, design, analysis
< Doosan ) ?eld !anu(acture, cree1 testing, design
< Alsto! +. ) #aterials, !echanical & cree1 testing, Euro1ean R&D liaison
< 'oodwin ) #aterials, casting, de%elo1!ent, 8 tonne :&aseline; cast
< N"* ) D-C strain !onitoring, ET#T !iniature testing
< *+ ) Electron !etallogra1hy, !odelling, !aterials de%elo1!ent
A""ocate"
< Tata ) s!all scale 1ilot !elts, steel!a9ing consultancy
A
#ARBN ) A no%el high alloy steel (or 1ower 1lant
,34+" to 'ate ) *ow alloy cree1 resisting steels ) ,BCr#o, Cr#o
Cerritic structure, li!ited car&ide strengthening
A11lications u1 to a&out @34 - @D4EC !aFi!u!
,35+" 'evelopment ) "G5 or :#odi(ied GHCr; steel
-ntroduced (ro! early 5GG4s onwards ) coal 1lant &oiler headers and dru!s /+. (irst0,
stea! 1i1ewor9 and HR$' a11lications worldwide
#artensitic structure ) (ine scale lath structure (or increased cree1 strength
Car&ide 1reci1itate chains on lath &oundaries
anadiu! !odi(ied to add (iner-scale networ9 o( %anadiu! nitride 1reci1itates
A11lications generally u1 to a&out @84EC /or higher i( at low stress0
,33+ - (+++ ) "G, steel
Re1lace !oly&denu! with tungsten in "G5 ) $o!e strength increase
A11lications ) e.g. A44EC !ain stea!, A,4EC hot reheat
TodayIs leading alloy ) The end o( the line (or !artensiticsJ
D
#ARBN ) A no%el high alloy steel (or 1ower 1lant
Euro1ean :CO$T; 1rogra!!e ) De%elo1ing alternati%es to "G5 = "G,
$o!e success ) e.g. &# #5, alloy (or &etter oFidation resistance /tu&ing0
CB, and CB, alloys (or large tur&ine co!1onents - slightly &etter than "G,
EF1eri!ental &oron additions ) -nconsistent results
$o!e !aterials showing 1ro!ise ) Cree &oron can segregate to inter(aces and hence
sta&ilise the car&ide structure - &ut this a11eared hard to control
The &rea9through ) By Cu2io A&e, N-#$, >a1an
Boron and nitrogen !ust &e controlled together
/hence :MARBN; ) MARtensite 1lus Boron 1lus Nitrogen0
?hen too !uch B and N are added ) Boron nitride /BN0 1reci1itates (or!
This re!o%es (ree &oron (ro! solution and strengthening is lost
$o ) Care(ul !icroalloying with B and li!ited N achie%es high cree1 strength
A winning co!&inationJ /&ut is this reci1e too co!1leF to &e co!!ercialJ0
8
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"u&lished #ARBN cree1 data ) N-#$ and T+ 'raK
N-#$ data ) 5A4B 8@N steel
$i!ilar to 'raK N"#5 data
/5,4B 564N0
?eld HAL (ailure li9ely
at lower stresses
#ARBN retains 64HM
cree1 strength ad%antage
o%er "G, in longer ter!
accelerated tests
A 1ro&le! with cree1 testing at A@4EC - *ong ter! tests are needed
to show the weld strength reduction. -n -#"ACT, test at AD@EC
NPM, an' A6e 'ata# 74+8C
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"G, !ean
N"#5 1arent
N"# cross-weld
A&e 5A4B 8@N 1arent
A&e 5A4B 8@N Fweld
:$38A6; trial !elt /rolled 1late0 ) To !atch N"#5.
$38A6 nor!alised at 55@4EC
Cree1 tests at AD@EC ) to 6444h
Broadly si!ilar results
to N-#$ = 'raK
when eF1ressed as H o(
ECCC !ean "G, cree1 strength
- O&tained in a shorter ti!e
NPM, an' A6e 'ata# 74+8C# pl0" IMPACT 'ata# 794C - Parent
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A&e 5A4B 8@N
$38A6, N55@4
#ARBN shows greatest ad%antages o%er "G, at inter!ediate stress
High stress NHot tensile test
*ow stress N*ong eF1osure, reduced 1reci1itate strengthening /all alloys0
55
:$38A6; trial !elt /rolled 1late0 ) To !atch N"#5.
?eld data now included.
-#"ACT results at AD@EC
again !atch 'raK A@4EC data
(airly well
?eld strength reduction !ay &e
slightly less at AD@EC than A@4EC
-#"ACT results con(ir! that
the #ARBN HAL is not i!!une
(ro! :Ty1e -; cree1 (ailure
at lower stresses,
- &ut data still &etter than parent "G,O
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"G, !ean
N"#5 1arent
N"#5 cross-weld
A&e 5A4B 8@N 1arent
A&e 5A4B 8@N Fweld
N"#5 Fweld (ail 1arent
$38A6N55@4 1arent
$38A6N55@4 Fweld
5,
"ro2ect $u!!ary ) Alloy De%elo1!ent
55 s!all %acuu! !elts and 8 %ariant air !elts !ade and cree1
tested
ariations in alloy content, B and N le%els, 1rocessing, heat
treat!ent
acuu! !elts tested a(ter rolling to 1late, nor!alising and te!1ering
Air !elts tested in the as-cast /N&Td0 condition
3 air !elt %ariants also tested a(ter rolling to 1late and N&T
8 %ariants /3 cast, 3 rolled0 also welded /-NA,@0 and cross-weld
cree1 tested
Ty1ically 3 cree1 tests 1er 1arent or cross-weld alloy %ariant
Tested out to P6,444h at AD@EC ) eQui%alent to 56.h at A@4EC on
*#" &asis
56
Alloy de%elo1!ent ) .ey Results
$i!1le air !elting 1ro%es uncertain ) hard to control N and deoFidation ) not
reco!!ended (or #ARBN 1roduction, &ut use(ul in alloy de%elo1!ent
Considera&le %ariation in results ) &ut a su&stantial range o( %ariants show cree1
strength at least ,4-64H higher than "G, within test condition range
HAL strength reduction a11lies, &ut #ARBN again !uch &etter than "G,
Rolled 1roducts show su&stantially 1oorer cree1 strength, &ut &etter ductility, than
corres1onding as-cast !aterials
Ruality heat treat!ent and 1rior steel 1rocessing conditions su&stantially a((ect cree1
1er(or!ance
Ther!odyna!ic !odelling use(ully clari(ies roles o( BN, &orides, etc
O1ti!ised co!1osition de%elo1ed (or 1ilot scale !anu(acture
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8 tonne !elt ) Cast 1late ) Co!1arati%e short ter! cree1
data ) A%eraged %alues (or each !aterial %ariant
'A# S 'oodwin air !eltT !ar9s 8T !elt
$0t"'e
'evelope'
"pecfcaton
In"'e
'evelope'
"pecfcaton
Improve'
heat
treatment
-!1ro%ed heat treat!ent ) The -#"ACT way (orward
Too little B and N ) Not enough car&ide sta&ilisation, and not enough N (or!ed
Too !uch B and N ) All the B and N %anish into useless large BN inclusions
Also ) BN tends to (or! at te!1eratures around 54@4-5544EC in casting and 1rocessing
) $o con%entional :nor!alising; heat treat!ent te!1eratures /e.g. 5434-5544EC (or
"G50 are not well o1ti!ised.
T+ 'raK de%elo1!ent ) Nor!alise at 55@4EC
-#"ACT /*ough&orough +ni%ersity0 showedT This still does not dissol%e all BN
Recommen'aton< Normal"e at ,(++8C to re'""olve all BN =an' control allo*
6alance to prevent 'elta ferrte formaton at that temperat0re>
IMPACT 'ata "ho! . Th" can a'' ? ,+-,4: to creep "tren2th
an' . The ran2e of accepta6le B an' N level" al"o !'en"
How !uch stronger is #ARBNJ
#ean data analysisT Ty1ical result is ,4-34H stronger than !ean "G,
/short ter! data0
Hence ) ta9e #ARBN as 64H stronger than "G,
"ossi&le 54HM (urther i!1ro%e!ent ) o1ti!ise HT
"ossi&le reduction ) in long ter! lower stress data
*ower &ound analysisT "oorest #ARBN cast - 5,4H !ean "G, strength
"oorest "G, !aterial ) 84H !ean "G, strength
$o ) Design %alue is &ased on lower &oundT
Design strength U#ARBN = "G,V S =,(+ @ 5+>
So . ar20a6l* - MARBN " 4+:"tron2er than P3(A
#ARBN ) Narrow range in strength, wide range in
co!1osition
/lement Cr Co B Mo C N6 B N Al BDN
!t : !t : !t : !t : !t : !t : ppm ppm ppm ppm
Maxm0m 5-3 %-( %-, +-, +-(( +-,, ,34 (,+ (++ %5+
Mnm0m 5-7 (-5 (-4 +-+, +-,3 +-+7 3+ ,4+ 4+ (54
The range o( cree1 strength %alues )
co!!only assu!ed to &e ty1ically M=- ,4H
(or a s1eci(ied alloy, is Quite narrow.
Howe%er, the range o( co!1ositions
included in the corres1onding siF %ariant
!aterials is Quite wide.
$o, #ARBN 1ro1erties are not critically de1endent on 1recise control o(
che!istry. On the contrary, Quite wide ranges are acce1ta&le.
Also 1lease note, the a&o%e !ay not always &e the widest acce1ta&le ranges )
they are !erely the li!iting %alues a11lying to the %ariants we !adeO
?hy is #ARBN !ean cree1 strength 64)34H W "G,J
Two !ain 1ossi&ilitiesT
/50 ) :GCr6?6Co; &ase alloy is intrinsically stronger than "G,, GCr4.@#o5.8?
/,0 - Control o( B and N content is crucial strengthening (actor
?hich is do!inantJ
-#"ACT also de%elo1ed trial alloys &ased on "G, &ut with controlled B and N
Best result was ) 56H stronger than the !ean (or nor!al "G,
Howe%er, the nor!alising te!1erature was not o1ti!ised in this de%elo1!ent
8 tonne !elt data show ) 5,44EC nor!alising can add (urther 54HM strength
$o ) A tentati%e, a11roFi!ate esti!ate !ight &eT
Control of B an' N ma* acco0nt for "ome ?(+-(4: "tren2thenn2
Intrn"c a'vanta2e" of 3Cr%B%Co ma* acco0nt for "ome ?,+-,4:
- &ut !ore wor9 is needed to clari(y these (actors
Trial !elts ) To !atch N"#5, and lower N alternati%e
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534B 8@N
534B 8@N weld
$38A6 534B 5@4N
$38A6 534B 5@4N weld
Ai! Actual
B 5A4 534
N 8@ 8@
B 5,4 534
N 564 5@4
A&e lower N co!1osition
'raK N"#5 co!1osition
?eld strength reduction ) so!e initial co!!ents
As shown &y T+ 'raK, #ARBN is not i!!une to weld HAL crac9ing
Reducing nitrogen to 8@11! does not a%oid the 1ro&le!
Note that A&e has shown that i( N is reduced to the P54 11! le%el, weld
HAL crac9ing " certainly eli!inated ) &ut the 1arent steel is then wea9er
Cailure in welds with nic9el alloy (illers is o(ten 1artially along the (usion line,
then 1artially through the HAL. This increases the stress acting on the HAL
and !ay 1roduce 1essi!istic data on weld 1er(or!ance. A !atching (erritic
(iller could there(ore 1ro&a&ly 1roduce a &etter result
#ARBN shows a su&stantial weld strength reduction, &ut it !ay well &e a
lesser 1ercentage than is a11lica&le e.g. to "G5 or "G,
-n any case, #ARBN is a !uch stronger steel than "G,O
,5
8 Tonne AOD !elt success(ully 1roduced
O1ti!ised IMPACT #ARBN steel co!1osition, including 1ractical
1ro%isions (or control o( !inor ele!ents and i!1urities, success(ully a11lied
in scaling-u1 to 8 tonne AOD !elt 1roduction
'oodwin 8T !elt 1oured in #ay ,45,
"roducts 1roducedT
- $!all 5@4F5@4!! ingots (or (orging = rolling to a trial wrought 1roduct
- *arger O, ingot a%aila&le - 1otential !anu(acture o( thic9 /1i1eJ0 1roduct
- 6 tonne :&onnet; sha1ed casting to si!ulate a ty1ical tur&ine co!1onent
- Cast !aterial test 1lates and weld 1lates
,,
8 Tonne #elt "roduction ) #ay ,45,
Courtesy o( 'oodwin $teel Castings *td
"hotogra1hs &y Ryan #c*achlan and *etian *i, *ough&orough +ni%ersity
6,@44.g -ngot Cast Test "lates
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NeFt $te1s ) Testing the 8 Tonne #elt
$hort ter! cree1 tests at AD@EC )conditions to !atch de%t. 1rogra!!e
-n%estigate e((ect o( 1roduct (or! ) casting, (orging, section siKe ) to (ollow
-n%estigate e((ects o( heat treat!ent %aria&les, o1ti!ise te!1ering
De%elo1 !anu(acturing, welding 1rocedures (or tu&e 1lant trial - ongoing
#ediu! ter! cree1 tests at AD@EC, A@4EC and A,@EC - "lanned
"arent and cross-weld
Critical e%aluation and data co!1arison with alternati%e #ARBN 1roducts,
which ha%e !ainly &een tested at A@4EC
*ong ter! tests &eyond ,456 ) ReQuired (or #ARBN design code a11ro%al
+. ) Ai! 1ri!arily to test (orged and welded !aterial
Corging o( ingot to &ar (or /!achined0 tu&e !anu(acture ) under way
,3
NeFt $te1s ) #ARBN $teel
A real ad%antage o%er "G, ) "otential (or ,4ECM 1lant u1ratingJ
E%olution %ersus re%olution ) ?hy see9 !ore no%el ideas, when we already
ha%e a su&stantially 1ro%en conce1t which we ha%e not yet i!1le!entedJ
Needed ) *ong ter! design data
Needed ) Realistic data (or long ter!, lower stress, welded a11lications
Needed ) Characterisation and Quality assess!ent o( large sha1ed casting
Needed ) De%elo1!ent o( 1i1e !anu(acture
Needed ) De%elo1!ent o( !atching welding consu!a&les
Needed ) #odelling o( long ter! degradation !echanis!s /e.g. L, *a%es0
Needed ) Euro1ean colla&oration into the (uture
IMPACT has eFtensi%e data and eF1erience to o((er - (or the neFt ste1sO
,@
NeFt $te1s ) -#"ACT and .##--N
.##--N ) The successor organisation to CO$T in Euro1ean colla&oration
-#"ACT steel - "otentially a%aila&le (ree to .##--N 1artner=s and others
$u&2ect to suita&le colla&oration agree!ent
Cast !aterial /either 1late or sha1ed casting0 a%aila&le now (or cree1 testing
*arge :&onnet; casting a%aila&le (or 1roduct characterisation and high te!1erature
!echanical testing /e.g. stress ru1ture, *CC, tensile, i!1act, welding and weld
1er(or!ance,etc0 /64E seg!ent re!o%ed in as-cast conditionT !ain casting a%aila&le
(or (ull-scale Quality heat treat!ent0
Cou1ons etc a%aila&le (or stea! oFidation testing
5@4F5@4!! ingot=s a%aila&le (or tu&e !anu(acture
*arge :O,; octagon ingot a%aila&le to de%elo1 1i1e !anu(acture
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NeFt $te1s ) -#"ACT and &eyond
Cast !aterial testing ) "lans now &eing wor9ed u1 (or long ter! cree1
testing and (atigue = cree1-(atigue testing at three Euro1ean la&oratories
Cou1ons (or stea! oFidation testing ) #ulti-la&oratory 1ro2ect &eing
wor9ed u1 ) #ARBN !ay ha%e a&nor!ally good oFidation resistance
ena&ling high te!1erature tu&ing a11lication, &ut not yet well understood.
5@4F5@4!! ingot=s (or tu&e !anu(acture ) -nterest in Euro1ean
de%elo1!ent o( con%entional /1ierced and drawn0 tu&e !a9ing 1rocess
O, octagonal ingot (or de%elo1!ent o( 1i1e !anu(acture ) +nder
discussion with a leading Euro1ean 1i1e !anu(acturer
?rought !aterial testing ) *ong ter! cree1 testing 1lanned in +.
+nder discussion ) ?elding de%elo1!ent using -#"ACT !aterial