MKM6144
ADVANCED MATERIAL
FACULTY OF MECHANICAL ENGINEERING
UNIVERSITI MALAYSIA PAHANG
Introduction
Subject
Course Code
Credits
Semester
Team Teaching
: ADVANCED MATERIAL
: MKM6144
: 4 Credits
: 2 2015/2016
: Dr. YULI PANCA ASMARA
Dr. TEDI KURNIAWAN
Dr. DANDI BACHTIAR
Dr. JANUAR PARLAUNGAN SIREGAR
Oxidation and Corrosion in
High-Temperature Systems
Course Description
Materials used for high temperature applications are subjected to various
types of degradation phenomenon such as high temperature corrosion,
erosion-corrosion, overheating, solid particle abrasion, wear, etc. Boiler
tubes used for super-heaters and re-heaters in steam-generating systems
are subjected to erosion-corrosion at high temperature, resulting in tube wall
thinning and premature failure. The present study investigates the high
temperature erosion-corrosion resistance of D-gun sprayed coatings on
ASTM-SA210-GradeA1 boiler tube steel in actual industrial environment.
SEM/EDAX, XRD and X-ray mapping analysis is done to reveal the
microstructural and compositional features of coated boiler tube steel. The
deposited coatings on Grade A1 steel exhibit uniform and dense
microstructure. Thermogravimetric technique is used to investigate the
erosion-corrosion behavior of uncoated and coated boiler tube steel at high
temperature for 1000 hours. SEM/EDAX, XRD and X-ray mapping techniques
were used to analyse the corrosion products.
Application
Gas Turbine and jet Turbine
Nuclear reactors
Power plants
Spacecraft
Chemical processing
Creep
Th = (tcreep+273)/(tmelting +273)
Th > 0.5 Creep is a concern
Creep test: measure dimensional changes
Focuses on early deformation stages
Creep conducts: Const Load Engineering
purpose
Stress Rupture test: effects of Temp on long time
load bearing characteristics, r.
Andrades Model
1.Sudden strain, 2.Transient
creepwith strain rate decrease
with time,
3. const rate creep
Garofalo Model:
MEASURING ELEVATED T RESPONSE
Elevated Temperature Tensile Test (T > 0.4 Tmelt).
creep test
x
.
slope =ss = steady-state creep rate
time
Generally,
. ceramics . metals
. polymers
ss
ss
ss
22
CREEP
Occurs at elevated temperature, T > 0.4 Tmelt
Deformation changes with time.
strain,
INCREASING T
tertiary
t
primary
secondary
elastic
0
T < 0.4 T
m
time
Adapted from
Figs. 8.26 and 8.27,
Callister 6e.
23
SECONDARY CREEP
Most of component life spent here.
Strain rate is constant at a given T,
--strain hardening is balanced by recovery
stress exponent (material parameter)
Q c
.
n
s K 2 exp
RT
strain rate
material const.
Strain rate
increases
for larger T,
activation energy for creep
(material parameter)
applied stress
200
100
Stress (MPa)
427C
40
20
10
1
10-2
10-1
Steady state creep rate s
538C
649C
Adapted from
Fig. 8.29, Callister 6e.
(Fig. 8.29 is from
Metals Handbook:
Properties and
Selection: Stainless
Steels, Tool Materials,
and Special Purpose
Metals, Vol. 3, 9th ed.,
D. Benjamin (Senior
Ed.), American Society
for Metals, 1980, p.
131.)
(%/1000hr)
24
CREEP FAILURE
Failure:
Estimate rupture time
along grain boundaries.
S 590 Iron, T = 800C, = 20 ksi
g.b. cavities
applied
stress
From V.J. Colangelo and F.A. Heiser, Analysis of
Metallurgical Failures (2nd ed.), Fig. 4.32, p. 87, John
Wiley and Sons, Inc., 1987. (Orig. source: Pergamon
Press, Inc.)
Time to rupture, tr
T(20 logtr ) L
temperature
function of
applied stress
time to failure (rupture)
Stress, ksi
100
20
10
data for
S-590 Iron
Adapted from
Fig. 8.45, Callister 6e.
(Fig. 8.45 is from F.R.
Larson and J. Miller,
Trans. ASME, 74, 765
(1952).)
1
12 16 20 24 28
L(103K-log hr) 24x103 K-log hr
T(20 logtr ) L
1073K
Ans: tr = 233hr
25
SECONDARY CREEP
Most of component life spent here.
Strain rate is constant at a given T,
--strain hardening is balanced by recovery
stress exponent (material parameter)
Q c
.
n
s K 2 exp
RT
strain rate
material const.
Strain rate
increases
for larger T,
activation energy for creep
(material parameter)
applied stress
200
100
Stress (MPa)
427C
40
20
10
1
10-2
10-1
Steady state creep rate s
538C
649C
Adapted from
Fig. 8.29, Callister 6e.
(Fig. 8.29 is from
Metals Handbook:
Properties and
Selection: Stainless
Steels, Tool Materials,
and Special Purpose
Metals, Vol. 3, 9th ed.,
D. Benjamin (Senior
Ed.), American Society
for Metals, 1980, p.
131.)
(%/1000hr)
24
TheCreepTest:
Applystresstoamaterialatanelevatedtemperature
Creep:Plasticdeformation
athightemperature
atypicalcreepcurveshowingthestrainproducedas
afunctionoftimeforaconstantstressandtemperature.
TheCreepTest:
Larson-Miller Parameter
Master plot for LarsonMiller parameter for S-590 alloy (an Febased alloy) (C = 17).
(From R. M. Goldhoff, Mater.Design Eng., 49 (1959) 93.)
Larson-Miller Equation
Relationship between time to rupture and
temperature at three levels of engineering
stress, a, b, and c, using LarsonMiller
equation (a > b > c).
Material Parameters
Diffusion Creep
Flow of vacancies according to (a) NabarroHerring and (b) Coble
mechanisms, resulting in an increase in the length of the specimen.
Coble creep:
a form of diffusion creep, is a mechanism for deformation of crystalline
solids. Coble creep occurs through the diffusion of atoms in a material
along the grain boundaries, which produces a net flow of material and a
sliding of the grain boundaries.
Coble creep is named after Robert L. Coble, who first reported his theory of
how materials creep over time in 1962 in the Journal of Applied Physics.
The strain rate in a material experiencing Coble creep is given by:
where
is the applied stress
d is the average grain boundary diameter
Dgb is the diffusion coefficient in the grain boundary
QCoble is the activation energy for Coble creep
R is the molar gas constant
T is the temperature in Kelvin
Note that in Coble creep, the strain rate
is proportional to the
applied stress ; the same relationship is found for Nabarro-Herring
creep. However, the two mechanisms differ in their relationship
between the strain rate and grain size d. In Coble creep, the strain rate
is proportional to d 3, whereas the strain rate in Nabarro-Herring
creep is proportional to d 2. Researchers commonly use these
relationships to determine which mechanism is dominant in a material;
by varying the grain size and measuring how the strain rate is affected,
they can determine the value of n in and conclude whether Coble or
Nabarro-Herring creep is dominant.
Dislocation Climb
Dislocation climb (a) upwards, under compressive 22
stresses, and (b) downwards, under tensile 22 stresses.
Dislocations Overcoming Obstacles
Weertman Mechanism
Dislocation overcoming obstacles by climb, according to Weertman theory.
(a) Overcoming CottrellLomer locks. (b) Overcoming an obstacle.
Grain Boundary Sliding
(a) Steady-state
grain-boundary sliding with
diffusional accommodations.
(b) Same process as in (a), in an
idealized polycrystal; the dashed
lines show the flow of vacancies.
(Reprinted with permission from
R. Raj and M. F. Ashby, Met. Trans.,
2A (1971) 1113.)
Ashby-Verralls Model
Grain-boundary sliding assisted by diffusion in AshbyVerralls model.
(Reprinted with permission from M. F. Ashby and R. A. Verrall, Acta Met., 21 (1973) 149.)
Deformation mechanism maps
These are graphs in typically stress-temperature space (but also grain size-temperature
and others) which show which deformation mechanisms dominate under which conditions
Deformation mechanism
maps
These are graphs in typically
stress-temperature space (but
also grain size-temperature and
others) which show which
deformation mechanisms
dominate under which conditions
Superplasticity
Superplastic tensile deformation in Pb62% Sn eutectic alloy tested
at 415 K and a strain rate of 1.33 104 s1; total strain of 48.5.
(From M. M. I. Ahmed and T. G. Langdon, Met. Trans. A, 8 (1977) 1832.)
Plastic Deformation
(a) Schematic representation of plastic deformation in tension
with formation and inhibition of necking. (b) Engineeringstress engineering-strain curves.
Strain Rate Dependence
Strain-rate dependence of (a) stress and (b) strain-rate sensitivity for
MgAl eutectic alloy tested at 350 C (grain size 10 m).
(After D. Lee, Acta. Met., 17 (1969) 1057.)
Fracture
Tensile fracture strain and stress as a function of strain
rate for Zr22% Al alloy with 2.5-m grain size.
(After F. A. Mohamed, M. M. I. Ahmed, and T. G. Langdon, Met. Trans. A, 8 (1977) 933.)
Effect of Strain Rate Sensitivity
Effect of strain-rate sensitivity m on maximum tensile
elongation for different alloys (Fe, Mg, Pu, PbSr, Ti, Zn, Zr based).
(From D. M. R. Taplin, G. L. Dunlop, and T. G. Langdon, Ann. Rev. Mater. Sci., 9 (1979) 151.)
Cavitation in Superplasticity
Cavitation in superplasticity formed 7475-T6 aluminum alloy ( = 3.5) at
475 C and 5 104 s1. (a) Atmospheric pressure. (b) Hydrostatic
pressure P = 4 MPa. (Courtesy of A. K. Mukherjee.)
Effect of Grain Size on Elongation
(a) Effect of grain size on
elongation: (A) Initial
configuration. (B) Large
grains. (C) Fine grains (10 m)
(Reprinted with permission from
N. E. Paton, C. H.
Hamilton, J. Wert, and M.
Mahoney, J. Metal, 34 (1981) No. 8,
21.)
(b) Failure strains
increase with superimposed
hydrostatic pressure (from 0 to 5.6
MPa). (Courtesy of
A. K. Mukherjee.)
Microstructure of a Creep resistant steel
HeatResistingSteel
Precipitates
M23C6 , M7 C3 , M2X ,
M3 C , M6 C , M X
Alloying Elements
Substitutional :
Creep Resistant Steel
Cr, V, Nb, Mo,W, Cu, Mn
Interstitial :
C, N
Intermetallics
Laves Phase, Z-Phase
Microstructure
Tempered Martensite,
Bainite
ResistancetoCreep
Solidsolutionhardening
Precipitatehardening
Microstructure
Thanks
