考虑拘束效应的高温下含缺陷P92管道寿命评估方法研究
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摘要
拘束效应是影响含缺陷结构在高温下裂纹起裂和扩展的重要因素。裂纹深度和结构几何尺寸的变化都会引起裂纹尖端拘束效应的变化，从而影响含缺陷结构的剩余蠕变寿命。因此研究拘束效应对蠕变裂纹扩展的影响，建立考虑拘束效应的寿命评估方法，对保证高温下含缺陷结构的安全运行具有重要意义。本文以超超临界火电机组用钢P92钢为研究材料，结合试验手段以及数值模拟技术，定性和定量的研究了拘束效应对蠕变裂纹扩展的影响。
利用小冲孔蠕变试验技术，通过和相应的单轴蠕变试验结果进行对比，建立了小冲孔蠕变的载荷和应力以及挠曲变形和应变之间的转换关系，获得了P92钢焊接接头各微区如母材、焊缝金属、粗晶区和细晶区的蠕变性能。
采用初始裂纹位于焊接接头不同微区的蠕变裂纹扩展试验，获得了P92钢各微区抗蠕变裂纹扩展能力，得到了蠕变裂纹扩展速率和高温断裂参量C*的关系。在相同的C*值下，最大的蠕变裂纹扩展速率出现在细晶区中，细晶区的蠕变裂纹扩展速率值是母材的2倍左右，主要和这个区域具有比较低蠕变强度和较高的拘束程度相关。
基于蠕变连续损伤力学，开发了蠕变裂纹扩展数值模拟技术。有限元计算的裂纹扩展情况和试验结果相一致，还清楚的反映了裂纹扩展过程中裂纹尖端区域蠕变损伤、应力以及应变的变化情况。
利用不同裂纹深度以及不同几何尺寸的试样进行了蠕变裂纹扩展试验，结果表明：裂纹深度以及试样几何尺寸变化引起的拘束效应，对蠕变裂纹扩展速率a和C*的关系具有重要影响。随后，利用蠕变裂纹扩展数值模拟技术，获得了不同裂纹深度以及不同几何尺寸试样，在蠕变裂纹扩展过程中裂纹尖端应力以及拘束参量Q的变化情况。建立了基于C*-Q双参量法的修正的蠕变裂纹扩展速率预测方法。与单参量C*的预测结果相比，在同样的C*值下，双参量预测的蠕变裂纹扩展速率值和试验结果具有较好的一致性，可以用来为含缺陷结构提供更准确的剩余蠕变寿命，保证其高温结构完整性。
The constraint level could affect the incubation and propagation of crack in thecomponents containing defects at high temperature. The variation of crack depth andstructure size would induce the variation of crack tip constraint. As a result, theresidual creep life of the components would be changed. Hence, understanding theeffect of constraint on creep crack behavior and establishing the correspondingresidual life assessment approach played an important role in assuring the reliabilityof the component with the presence of defects at elevated temperature. In this paper,the effect of constraint on the creep crack growth property was qualitatively studiedand quantitatively characterized, which were carried out on ASME P92steel mainlyapplied in Ultra Supercritical Power Plants Components by experimental investigationand numerical simulation.
The creep properties of distinct zones of P92steel welded joint, i.e. base metal(BM), welded metal (WM), coarse grain heat affected zone (CGHAZ) and fine grainheat affected zone (FGHAZ), were obtained using small punch creep test method.This was achieved by establishing the relationship of load in small punch creep testand stress in uniaxial creep test and by determining the correlation of deflection andstrain on the basis of the comparison of uniaxial creep results and small punch creepresults.
The creep crack growth tests were carried out on the specimens with initial crackslocated in the welded joint distinct zones to determine the creep crack growthproperties of micro zones of P92steel welded joint. The relationships between creepcrack growth rate a and high temperature parameter C*for micro zones of weldedjoint were obtained. The results revealed that at the same value of C*, the highestcreep crack growth rate occurred in the FGHAZ specimen while the lowest presentedin the BM specimen. This was due to the fact that the creep properties of FGHAZspecimen was low and the constraint in it was high compared with those of othermicro zones.
Based on creep continuum damage mechanics and coupled with finite elementmethod analysis, the virtual creep crack growth technique was achieved. The creepcrack growth behaviors calculated by numerical simulation exhibited agreement withthose of experimental data. Furthermore, the evolution of the creep damage and the variation of stress and strain in the crack tip zone during creep crack propagationprocess were also obtained.
Creep crack growth tests with specimens of various crack depths and specimensizes were carried out to investigate the effect of constraint on the creep crack growthbehavior. The tested results revealed that the constraint induced by crack depth andspecimen size could affect the relationship between creep crack growth rate a andC*. Then, the variations of the crack tip stress distribution and the constraintparameter Q during creep crack growth process were obtained using creep crackgrowth numerical simulation. Furthermore, a modified creep crack growth predictionapproach based on the C*-Q theory was proposed. Compared with conventionalpredictions provided by single C*parameter, the creep crack growth rate determinedby the modified C*-Q approach exhibited agreement with experimental results andnumerical results as the value of C*was the same. These phenomena meant that thisapproach could be employed to give a more accurate residual creep life and to assurethe reliability for the in-service components with defects at elevated temperature.
利用小冲孔蠕变试验技术，通过和相应的单轴蠕变试验结果进行对比，建立了小冲孔蠕变的载荷和应力以及挠曲变形和应变之间的转换关系，获得了P92钢焊接接头各微区如母材、焊缝金属、粗晶区和细晶区的蠕变性能。
采用初始裂纹位于焊接接头不同微区的蠕变裂纹扩展试验，获得了P92钢各微区抗蠕变裂纹扩展能力，得到了蠕变裂纹扩展速率和高温断裂参量C*的关系。在相同的C*值下，最大的蠕变裂纹扩展速率出现在细晶区中，细晶区的蠕变裂纹扩展速率值是母材的2倍左右，主要和这个区域具有比较低蠕变强度和较高的拘束程度相关。
基于蠕变连续损伤力学，开发了蠕变裂纹扩展数值模拟技术。有限元计算的裂纹扩展情况和试验结果相一致，还清楚的反映了裂纹扩展过程中裂纹尖端区域蠕变损伤、应力以及应变的变化情况。
利用不同裂纹深度以及不同几何尺寸的试样进行了蠕变裂纹扩展试验，结果表明：裂纹深度以及试样几何尺寸变化引起的拘束效应，对蠕变裂纹扩展速率a和C*的关系具有重要影响。随后，利用蠕变裂纹扩展数值模拟技术，获得了不同裂纹深度以及不同几何尺寸试样，在蠕变裂纹扩展过程中裂纹尖端应力以及拘束参量Q的变化情况。建立了基于C*-Q双参量法的修正的蠕变裂纹扩展速率预测方法。与单参量C*的预测结果相比，在同样的C*值下，双参量预测的蠕变裂纹扩展速率值和试验结果具有较好的一致性，可以用来为含缺陷结构提供更准确的剩余蠕变寿命，保证其高温结构完整性。
The constraint level could affect the incubation and propagation of crack in thecomponents containing defects at high temperature. The variation of crack depth andstructure size would induce the variation of crack tip constraint. As a result, theresidual creep life of the components would be changed. Hence, understanding theeffect of constraint on creep crack behavior and establishing the correspondingresidual life assessment approach played an important role in assuring the reliabilityof the component with the presence of defects at elevated temperature. In this paper,the effect of constraint on the creep crack growth property was qualitatively studiedand quantitatively characterized, which were carried out on ASME P92steel mainlyapplied in Ultra Supercritical Power Plants Components by experimental investigationand numerical simulation.
The creep properties of distinct zones of P92steel welded joint, i.e. base metal(BM), welded metal (WM), coarse grain heat affected zone (CGHAZ) and fine grainheat affected zone (FGHAZ), were obtained using small punch creep test method.This was achieved by establishing the relationship of load in small punch creep testand stress in uniaxial creep test and by determining the correlation of deflection andstrain on the basis of the comparison of uniaxial creep results and small punch creepresults.
The creep crack growth tests were carried out on the specimens with initial crackslocated in the welded joint distinct zones to determine the creep crack growthproperties of micro zones of P92steel welded joint. The relationships between creepcrack growth rate a and high temperature parameter C*for micro zones of weldedjoint were obtained. The results revealed that at the same value of C*, the highestcreep crack growth rate occurred in the FGHAZ specimen while the lowest presentedin the BM specimen. This was due to the fact that the creep properties of FGHAZspecimen was low and the constraint in it was high compared with those of othermicro zones.
Based on creep continuum damage mechanics and coupled with finite elementmethod analysis, the virtual creep crack growth technique was achieved. The creepcrack growth behaviors calculated by numerical simulation exhibited agreement withthose of experimental data. Furthermore, the evolution of the creep damage and the variation of stress and strain in the crack tip zone during creep crack propagationprocess were also obtained.
Creep crack growth tests with specimens of various crack depths and specimensizes were carried out to investigate the effect of constraint on the creep crack growthbehavior. The tested results revealed that the constraint induced by crack depth andspecimen size could affect the relationship between creep crack growth rate a andC*. Then, the variations of the crack tip stress distribution and the constraintparameter Q during creep crack growth process were obtained using creep crackgrowth numerical simulation. Furthermore, a modified creep crack growth predictionapproach based on the C*-Q theory was proposed. Compared with conventionalpredictions provided by single C*parameter, the creep crack growth rate determinedby the modified C*-Q approach exhibited agreement with experimental results andnumerical results as the value of C*was the same. These phenomena meant that thisapproach could be employed to give a more accurate residual creep life and to assurethe reliability for the in-service components with defects at elevated temperature.
引文
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