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Fatigue Performance of an Improved Creep Strength 10%Cr Steel

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Abstract

The deployment of 9-12% Cr steels for elevated temperature applications up to 650 °C presents a cost-effective alternative to more expensive nickel-based alloys in steam turbine power generation. To enhance creep resistance at this temperature range, a novel ferritic-martensitic steel, designated CPJ7, was developed and fabricated at the National Energy Technology Laboratory. The alloy design aimed to mitigate the transformation of strengthening carbides into deleterious phases that degrade creep performance. Results have demonstrated that CPJ7 exhibits favorable creep and oxidation resistance at 650 °C. However, its fatigue performance remains unexplored. This study builds upon prior research by evaluating the low cycle fatigue behavior of CPJ7 and verifying that modifications beneficial to creep performance were not detrimental to the fatigue performance. The alloy was tested at both 650 °C and ambient temperature under fully reversed bending conditions (R = − 1) and a load ratio of 0.05. The alloy exhibits cyclic softening, a behavior consistent with other 9-10 wt.% Cr steels. Analysis of the microstructure and hysteresis loops further corroborate cyclic softening mechanisms typical of ferritic-martensitic steels. Overall, the fatigue performance of CPJ7 meets or exceeds that of P91 steel, demonstrating its potential for high-temperature structural applications.

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Abbreviations

LCF:

Low cycle fatigue

N f :

Failure cycle

K :

Stress intensity factor

Δε :

Strain range

σ f :

Is the frictional stress

σ max :

Is the maximum stress from the half hysteresis loop

σ y :

Is the yield stress

σ b :

Is the back stress

PAG:

Prior austenite grain

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Acknowledgment

This work was performed in support of the U.S. Department of Energy’s Fossil Energy and Carbon Management’s Advanced Energy Materials Research Program and executed through the National Energy Technology Laboratory (NETL) Research & Innovation Center’s Advanced Alloy Development FWP. The authors would like to thank Mr. Argetsinger and Mr. Mendenhall for assistance in melting and Mr. Powell for mechanical testing.

Funding

This project was funded by the U.S. Department of Energy, National Energy Technology Laboratory, in part, through a site support contract. Neither the United States Government nor any agency thereof, nor any of their employees, nor the support contractor, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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  1. National Energy Technology Laboratory, 1450 Queen Avenue SW, Albany, OR, 97321, USA

    Kyle Rozman, Jeff Hawk, Martin Detrois & Paul Jablonski

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Rozman, K., Hawk, J., Detrois, M. et al. Fatigue Performance of an Improved Creep Strength 10%Cr Steel. J. of Materi Eng and Perform (2025). https://doi.org/10.1007/s11665-025-12180-8

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