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Creep-Resistant Ferritic-Martensitic Steels for Power Plant Applications

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Abstract

Creep-resistant ferritic-martensitic steels are essential materials used in power plants for electricity generation. The efficiency and emissions of the plant are closely related to the operating temperature. Materials used in the hottest sections are one of the main limiting factor for plant operation at 650 °C. This review describes the recent development of creep-resistant ferritic-martensitic steels from a large dataset of in-house research. The findings are tied to available literature for discussion. A first steel, CPJ-7, was developed with an operating temperature approaching 650 °C, and a refined design, JMP, showed the potential to operate at 650 °C. Approximately fifty different ingots, each weighing ~ 7 kg, were vacuum induction melted and processed. Overall, wrought and cast versions of CPJ-7 present superior creep properties when compared to wrought and cast versions of COST alloys for steam turbine and P91/92 for boiler applications. The prolonged creep life was attributed to slowing down the process of the destabilization of the MX and M23C6 precipitates at 650 °C. The cast version of CPJ-7 also revealed superior mechanical performance, above commercially available cast 9% Cr martensitic steel or derivatives. Following the work on CPJ-7, the JMP steels were designed with higher Co for increased solid solution strengthening, Si for oxidation resistance and increased W for matrix strength and stability. The JMP steels showed increases in creep life compared to CPJ-7 between 118 and 150% at 650 °C for testing at various stresses between 138 and 207 MPa. On a Larson–Miller plot, the performance of the JMP steels surpasses that of state-of-the-art MARBN steel. The influence of various elements within the composition of the alloys on the microstructure and mechanical properties is discussed. This review presents approximately 420,000 h of in-house creep testing, the equivalent of almost 50 years of cumulative creep tests.

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Acknowledgments

This work was performed in support of the US Department of Energy’s Fossil Energy and Carbon Management Advanced Energy Materials Research Program executed under the Research and Innovation Center Advanced Alloys Development FWP. The authors would like to thank Dr. David Alman for program direction, Mr. Edward Argetsinger and Mr. Joseph Mendenhall for assistance in melting, Dr. Christopher Cowen for contributions to the research, Dr. Chang-Yu Hung and Dr. Stoichko Antonov for TEM on the JMP steels, Dr. Kyle Rozman for fractography and analysis and Mr. Christopher Powell for mechanical testing and data gathering. TEM imaging on the CPJ steels was provided through work funded as part of the National Energy Technology Laboratory’s Regional University Alliance (NETL-RUA), a collaborative initiative of the NETL, this technical effort was performed under the RES contract at Virginia Tech, M. Murayama (PI).

Funding

This project was funded by the US Department of Energy, National Energy Technology Laboratory, in part, through a site support contract. Neither the US 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 US Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the US Government or any agency thereof.

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

    Martin Detrois, Jeffrey A. Hawk & Paul D. Jablonski

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  1. Martin Detrois
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  2. Jeffrey A. Hawk
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  3. Paul D. Jablonski
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Correspondence to Martin Detrois.

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Detrois, M., Hawk, J.A. & Jablonski, P.D. Creep-Resistant Ferritic-Martensitic Steels for Power Plant Applications. J. of Materi Eng and Perform 33, 1–42 (2024). https://doi.org/10.1007/s11665-023-08566-1

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