Power Plants. Structural Alloys for. Operational Challenges and. High-temperature Materials. Edited by. Amir Shirzadi and Susan Jackson.

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1 Woodhead Publishing Series in Energy: Number 45 Structural Alloys for Power Plants Operational Challenges and High-temperature Materials Edited by Amir Shirzadi and Susan Jackson AMSTERDAM BOSTON CAMBRIDGE HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO WP WOODHEAD PU BUSHING SAN FRANCISCO SINGAPORE SYDNEY TOKYO ELSEVIER Woodhead Publishing is an iinprim of Elsevier

2 Contents Contributor contact details Woodhead Publishing Series in Energy Preface xi xv xxi Part I Operational challenges and structural alloy requirements 1 1 Gas turbines: operating conditions, components and material requirements 3 A. W. James and S. Rajagopalan, Siemens Energy Inc., USA 1.1 Introduction Overview of materials systems and their role in gas turbines Operating conditions and materials selection Critical degradation mechanisms, aging and monitoring Materials performance assessment and life management Materials limitations, challenges and future directions Acknowledgements Sources of further information and advices References 20 2 Steam turbines: operating conditions, components and material requirements 22 S. Osgerby, Alstom Power, UK 2.1 Introduction High temperature cylinder components Factors affecting the service life of high temperature components Low temperature cylinder components Factors affecting the service life of low temperature components 31

3 vi Contents 2.6 Conclusion References 35 3 High temperature materials issues in the design and operation of coal-fired steam turbines and plant 36 F. Starr, Consultant, UK 3.1 Introduction Recent power plant history and its lessons Challenges of advanced plants Thermodynamics and design of the steam and water circuits Design and operation of furnace and boiler Superheater design issues Two shift cycling Material issues in the development of advanced steam plants Discussion Conclusions References 66 4 Nuclear power plants: types, components and material requirements 69 J. F. Knott, The University of Birmingham, UK 4.1 Introduction UK gas-cooled reactors: Magnox and advanced gascooled reactors (AGR) The pressurised water reactor (PWR) 'Generation IV systems: the fusion reactor Conclusion References 100 Part II Structural alloys and their development Austenitic steels and alloys for power plants 105 Y. Yin and R. Faulkner, Loughborough University, UK and F. Starr, Consultant, European Technology Ltd, UK 5.1 Introduction The Fe-C phase diagram and austenitic steels Microstructure and properties of austenitic steels Other problems with the use of austenitics Modern Japanese alloys Discussion and future work 146

4 Contents vii 5.7 Sources of further information and advice References Bainitic steels and alloys for power plants 153 M. J. Peet, University of Cambridge, UK 6.1 Introduction Transformations in steels Tempering heat treatment and service Desirable properties for high temperature components used in power plants Developments of bainitic power plant steels Conclusion References Ferritic and martensitic steels for power plants 188 P. J. Ennis, University of Leicester, UK 7.1 Introduction Metallurgical background Power plant ferritic, bainitic and martensitic steels Steam oxidation Production and fabrication of power plant components Power plant experience with most recently developed steels Further development of power plant steels Sources of further information and advice References and further reading Structural materials containing nanofeatures for advanced energy plants 221 W. Hoffelner, RWH consult GmbH, Switzerland 8.1 Introduction Oxide dispersion strengthening (ODS) Ferritic-martensitic ODS steels ODS materials based on a non-ferrous matrix Production of nanoparticles containing alloys and components Components manufactured from ODS alloys Properties of nanoparticle-containing steels Other nanofeatures used to strengthen alloys for high temperature applications Conclusion Acknowledgement References 243

5 viii Contents 9 Development of creep-resistant steels and alloys for use in power plants 250 F. Abe, National Institute for Materials Science (NIMS), Japan 9.1 Introduction Basic methods of strengthening steels and alloys at elevated temperatures Development progress of creep-resistant steels and alloys Degradation in creep strength of components subjected to elevated temperature Advanced alloy design of creep-resistant steels and Ni-base superalloys to mitigate materials degradation Conclusion and future trends References Development of advanced alloys with improved resistance to corrosion and stress corrosion cracking (SCC) in power plants 294 S. Prakash, Indian Institute of Technology, India 10.1 Introduction Overview of corrosion and stress corrosion Development of alloys Creep-fatigue behaviour of steels and superalloys Advanced design and use of alloys Future trends References and further reading Design and material issues in improving fracture/ fatigue resistance and structural integrity in power plants 319 J. F. Knott, The University of Birmingham, UK 11.1 Introduction Engineering design and brittle fracture Linear elastic fracture mechanics Yielding fracture mechanics: the failure assessment diagram (FAD) Brittle fracture in power plant steels Inter-granular fracture in turbine disc steel Potential concerns in nuclear reactor pressure vessel (RPV) steels Fatigue: S-N curves, Miner's Law, stress concentrators Fatigue crack propagation 340

6 Contents ix Fatigue induced by thermal strain Fatigue crack growth and interactions Conclusion References Radiation damage to structural alloys in nuclear power plants: mechanisms and remediation 355 G. S. Was, University of Michigan, General Electric Global Research, USA USA and P. L. Andresen, 12.1 Introduction Overview: the radiation damage event Physical degradation Stress-related degradation Environmental factors in cracking Environmental factors in fracture The response of stainless steel to irradiation The response of pressure vessel steels to irradiation The response of advanced alloys to irradiation Conclusion Sources of further information and advice References The use of advanced alloys to resolve welding problems in power plants 421 D. J. Abson, TWI, UK and G. Mathers, Consultant, UK 13.1 Introduction Parent steel behaviour and the analysis of creep rupture data Welding and the resulting residual stresses Advantages and limitations of particular alloys Advanced design and use of newer alloys Future trends Sources of further information and advice References and further reading Modelling creep in nickel alloys in high temperature power plants 447 H. V. Atkinson and S. P. A. Gill, University of Leicester, UK 14.1 Introduction Empirical methods Semi-empirical models Neural network approaches 453

7 x Contents 14.5 Physics-based approaches Conclusion References 474 Index 479