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Title: Multi Resolution In-Situ Testing and Multiscale Simulation for Creep Fatigue Damage Analysis of Alloy 617

Abstract

This report outlines the research activities that were carried out for the integrated experimental and simulation investigation of creep-fatigue damage mechanism and life prediction of Nickel-based alloy, Inconel 617 at high temperatures (950° and 850°). First, a novel experimental design using a hybrid control technique is proposed. The newly developed experimental technique can generate different combinations of creep and fatigue damage by changing the experimental design parameters. Next, detailed imaging analysis and statistical data analysis are performed to quantify the failure mechanisms of the creep fatigue of alloy 617 at high temperatures. It is observed that the creep damage is directly associated with the internal voids at the grain boundaries and the fatigue damage is directly related to the surface cracking. It is also observed that the classical time fraction approach does not has a good correlation with the experimental observed damage features. An effective time fraction parameter is seen to have an excellent correlation with the material microstructural damage. Thus, a new empirical damage interaction diagram is proposed based on the experimental observations. Following this, a macro level viscoplastic model coupled with damage is developed to simulate the stress/strain response under creep fatigue loadings. A damage rate function basedmore » on the hysteresis energy and creep energy is proposed to capture the softening behavior of the material and a good correlation with life prediction and material hysteresis behavior is observed. The simulation work is extended to include the microstructural heterogeneity. A crystal plasticity finite element model considering isothermal and large deformation conditions at the microstructural scale has been developed for fatigue, creep-fatigue as well as creep deformation and rupture at high temperature. The model considers collective dislocation glide and climb of the grains and progressive damage accumulation of the grain boundaries. The glide model incorporates a slip resistance evolution model that characterizes the solute-drag creep effects and can capture well the stress-strain and stress time response of fatigue and creep-fatigue tests at various strain ranges and hold times. In order to accurately capture the creep strains that accumulate particularly at relatively low stress levels, a dislocation climb model has been incorporated into the crystal plasticity modeling framework. The dislocation climb model parameters are calibrated and verified through experimental creep tests performed at 950°. In addition, a cohesive zone model has been fully implemented in the context of the crystal plasticity finite element model to capture the intergranular creep damage. The parameters of the cohesive zone model have been calibrated using available experimental data. The numerical simulations illustrate the capability of the proposed model in capturing damage initiation and growth under creep loads as compared to the experimental observations. The microscale analysis sheds light on the crack initiation sites and propagation patterns within the microstructure. The model is also utilized to investigate the hybrid-controlled creep-fatigue tests and has been found to capture reasonably well the stress-strain response with different hold times and hold stress magnitudes.« less

Authors:
 [1];  [2]
  1. Arizona State Univ., Tempe, AZ (United States). School for Engineering of Matter, Transport and Energy
  2. Vanderbilt Univ., Nashville, TN (United States). Dept. of Civil and Environmental Engineering
Publication Date:
Research Org.:
Arizona State Univ., Tempe, AZ (United States)
Sponsoring Org.:
USDOE Office of Nuclear Energy (NE)
OSTI Identifier:
1358190
Report Number(s):
13-5039
13-5039
DOE Contract Number:
NE0000675
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Liu, Yongming, and Oskay, Caglar. Multi Resolution In-Situ Testing and Multiscale Simulation for Creep Fatigue Damage Analysis of Alloy 617. United States: N. p., 2017. Web. doi:10.2172/1358190.
Liu, Yongming, & Oskay, Caglar. Multi Resolution In-Situ Testing and Multiscale Simulation for Creep Fatigue Damage Analysis of Alloy 617. United States. doi:10.2172/1358190.
Liu, Yongming, and Oskay, Caglar. 2017. "Multi Resolution In-Situ Testing and Multiscale Simulation for Creep Fatigue Damage Analysis of Alloy 617". United States. doi:10.2172/1358190. https://www.osti.gov/servlets/purl/1358190.
@article{osti_1358190,
title = {Multi Resolution In-Situ Testing and Multiscale Simulation for Creep Fatigue Damage Analysis of Alloy 617},
author = {Liu, Yongming and Oskay, Caglar},
abstractNote = {This report outlines the research activities that were carried out for the integrated experimental and simulation investigation of creep-fatigue damage mechanism and life prediction of Nickel-based alloy, Inconel 617 at high temperatures (950° and 850°). First, a novel experimental design using a hybrid control technique is proposed. The newly developed experimental technique can generate different combinations of creep and fatigue damage by changing the experimental design parameters. Next, detailed imaging analysis and statistical data analysis are performed to quantify the failure mechanisms of the creep fatigue of alloy 617 at high temperatures. It is observed that the creep damage is directly associated with the internal voids at the grain boundaries and the fatigue damage is directly related to the surface cracking. It is also observed that the classical time fraction approach does not has a good correlation with the experimental observed damage features. An effective time fraction parameter is seen to have an excellent correlation with the material microstructural damage. Thus, a new empirical damage interaction diagram is proposed based on the experimental observations. Following this, a macro level viscoplastic model coupled with damage is developed to simulate the stress/strain response under creep fatigue loadings. A damage rate function based on the hysteresis energy and creep energy is proposed to capture the softening behavior of the material and a good correlation with life prediction and material hysteresis behavior is observed. The simulation work is extended to include the microstructural heterogeneity. A crystal plasticity finite element model considering isothermal and large deformation conditions at the microstructural scale has been developed for fatigue, creep-fatigue as well as creep deformation and rupture at high temperature. The model considers collective dislocation glide and climb of the grains and progressive damage accumulation of the grain boundaries. The glide model incorporates a slip resistance evolution model that characterizes the solute-drag creep effects and can capture well the stress-strain and stress time response of fatigue and creep-fatigue tests at various strain ranges and hold times. In order to accurately capture the creep strains that accumulate particularly at relatively low stress levels, a dislocation climb model has been incorporated into the crystal plasticity modeling framework. The dislocation climb model parameters are calibrated and verified through experimental creep tests performed at 950°. In addition, a cohesive zone model has been fully implemented in the context of the crystal plasticity finite element model to capture the intergranular creep damage. The parameters of the cohesive zone model have been calibrated using available experimental data. The numerical simulations illustrate the capability of the proposed model in capturing damage initiation and growth under creep loads as compared to the experimental observations. The microscale analysis sheds light on the crack initiation sites and propagation patterns within the microstructure. The model is also utilized to investigate the hybrid-controlled creep-fatigue tests and has been found to capture reasonably well the stress-strain response with different hold times and hold stress magnitudes.},
doi = {10.2172/1358190},
journal = {},
number = ,
volume = ,
place = {United States},
year = 2017,
month = 4
}

Technical Report:

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  • A test program was conducted under contract to Sandia National Laboratories to investigate water/steam effects on elevated temperature low cycle fatigue and creep-fatigue of Alloy 800. This report presents interpretation and analysis of the test results. Tubular specimens with water sealed inside were cycled to failure under strain control. Tests were conducted to 616K (650/sup 0/F) and 922K (1200/sup 0/F); some at 922K included tensile or compressive hold periods to simulate creep-fatigue conditions. The tubular specimens showed significantly lower lives than solid bar specimens cycled at equivalent strain ranges. Rough internal surfaces contributed to early crack initiation with these specimens.more » Inclusion of hold periods caused further large reductions in cycles to failure.« less
  • Uniaxial low-cycle fatigue and creep-fatigue tests have been carried out on hollow alloy 800 specimens that were either filled with air or with a molten mixture of sodium nitrate, potassium nitrate and an oxidizer. Low-cycle fatigue tests were carried out at 1200/sup 0/F and 650/sup 0/F by cycling the strain continuously between equal mangitude of tensile and compressive values at a rate of 4 x 10/sup -3/sec/sup -1/ until failure. The creep-fatigue tests were carried out at 1200/sup 0/F. The loading cycle differed from that of low-cycle fatigue testing only in the imposition of a hold at the peak compressivemore » strain in each cycle. Cracks always initiated on the inner surface of the hollow specimen, and therefore, corrosive effects on crack propagation and initiation were controlled by the environment within the specimen cavity. In common with tests carried out earlier on steam-filled alloy 800 specimens, at 1200/sup 0/F in the presence of molten salt the heat of alloy 800 with the lower carbon content had a higher fatigue strength than the heat with the higher carbon content even though different heats were used in the two testing programs. The fatigue strength of the two heats of material in the presence of molten salt at 650/sup 0/F were about the same. Tests with air-filled specimens indicated that the presence of the molten salt degraded the fatigue life at 1200/sup 0/F but did not affect the creep fatigue life, while the presence of steam enhanced both the fatigue life and the creep-fatigue life.« less
  • Uniaxial low-cycle fatigue and creep-fatigue tests have been carried out on hollow alloy 800 specimens that were filled with steam. Two testing temperatures were employed, each with its own steam condition. These temperatures and steam conditions were 650/sup 0/F with saturated steam (5% liquid, 95% vapor) and 1200/sup 0/F with superheated steam at 2200 psi. The low-cycle fatigue tests were carried out at both 650/sup 0/F and 1200/sup 0/F by cycling the strain between equal tensile and compressive magnitudes until specimen failure or until it was no longer practical to continue the test. The creep-fatigue tests were carried out tomore » failure by cycling the strain in the same fashion as in the low-cycle fatigue tests but with holds imposed at either the peak tensile strain or the peak compressive strain or at both peak tensile and compressive strains in each loading cycle.« less