Fatigue - in - LWRs - Va Inox 304 PDF

FATIGUE in LWRs
International Conference on Plants Materials Degradation November 18-20 , 2008
J. MENDEZ (LMPM-ENSMA) J.M. STEPHAN (EDF)
LMPM
Plan
Solicitation and Materials Codes and Rules Questions to solve New Knowledge in Fatigue Behavior of austenitic stainless steel :
High cycle fatigue and fatigue limit Interaction between Low cycle and High cycle fatigue Environmental effects
2 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers
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Fatigue
Fatigue is defined as a term which "applies to changes in properties which can occur in a metallic material due to repeated application of stresses or strains, although usually this term applies specially to those changes which lead to cracking or failure"
(General Principles for Fatigue testing of Metals, 1964)
Fatigue is an ageing process !
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Fatigue
Fatigue is an important cause of incidents in NPPs :
Vibrations, Thermal stratification, Vortex in dead legs, Thermal mixing
Fatigue is cited in life extension of NPPs :

Residual life Upper probability of occurrence due to the accumulation of repeated loadings
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Origin of Fatigue in NPPs

Mechanical loadings :
Vibrations (70%)
Thermal loadings
Initially, fatigue incidents were due to large thermal loadings (Thermal Shocks, Stratification) Nowadays, thermal fatigue problems concern small random thermal cycles due to mixing or vortex
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Solicitations and Materials

Mechanical Solicitations
Vibrations
Most frequent fatigue type occurrence : ~70%
High cycle fatigue failure Mechanical or flow induced vibration loads Short time, during plant startup or soon thereafter, or after aging (wear, clearance) Design configurations, modifications, BWR power uprates
Locations
Small bore pipes Tube bundle (Alliage 600) Main steam systems nozzles for measurements Valves steam : when not tight close or opened : Valve relief "chattering"
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Thermal Solicitations
Thermal shocks following modification of plant condition
Not frequent but with high amplitude of temperature (270 C) Not localized (hitting the whole component) Vessel, pipes CVCS nozzle, SIS nozzle, Surge line (AISI 304, CF3, CF8)
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Thermal Stratification
Inherent under some operating conditions (low flow rates) Possible high stress ranges during flow rate variations Dependence on bearing modes Vessel, pipes : Surge line (AISI 304), Feedwater Flow Control Systems (A42, A48, 16MND5)
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Conclusion on large thermal loads :
Possible measurements on sites (outer wall) Now covered by existing rules and codes
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Vortex
Only damaging, if associated with abnormal conditions (valve leakage) Except in the case of non-insulated small diameter pipe Pipes : "Dead Legs" : SIS, RHR (AISI 304), small pipes linked to Primary Circuit
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Turbulent mixing
In general, localizations where thermal fluctuations can take place (piping mixing zones, pumps..) Inherent under functioning conditions of some systems (pipe junctions, pumps) Possible large damages Pipes : RHR (AISI 304, 316 ), CVCS (AISI 304, CF8, CF3 ), Pumps (AISI 304, 316, AISI 410)
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Conclusion on high cycle thermal loads :
No direct measurements on sites due to high frequencies involved Large non linear stresses gradient Complexity : links between thermal-hydraulics, mechanics (initiation and fracture), materials and plant operations Problem of multi-cracks Combination with low cycle fatigue : damage accumulation
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Codes and Rules

ASME Code Section III and VIII :
Recent proposed developments :
Revision of fatigue strength curves and margins Explicit inclusion of environmental effects Possibility to apply an "initiation + crack growth approach"
can have wide implications in industry
KTA = ASME
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Codes and Rules

RCCM :
Derived from ASME but with modifications :
Ke optimisation for stainless steels Ke for mechanical loads and possible Keth for thermal loads K for mixing zones Crack like defects fatigue analysis method
JSME :
Some dedicated standard for low and high cycles fatigue
WWER PNAE Code

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Fatigue : Main needs

Definition of screening values with simple parameters Guidelines to account for complex loadings like random loadings (associated or not with low cycle loads) Improvements in propagation threshold Material aspects : Improvements in fatigue curves to take into account surface finishes, mean stresses, welds, residual stresses, environment Probabilistic aspects in fatigue : random loads Interaction with variations in metal conditions (ageing, irradiation)
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Research Programs
Last decades :
Low cycles fatigue (Thermal shocks, Stratification) in pipes, nozzles, pumps
Now :
Major programs devoted to thermal cycling in mixing areas and vortex in dead legs
Thermal-hydraulics High cycles mechanical testing Material studies : T , Surface finishes, mean stres ses, environment
Research at the micro and meso level : Dislocations, Aggregates
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Questions to solve : Thermal Hydraulics

Experimental :
Quality of on site measurements (external wall) or mock-up measurements (fine measurements on the surface) Transposition methodologies
Numerical :
Quality of numerical simulations :
R.A.N.S. simulation (mean thermal-hydraulic flows) Large Eddy simulations (LES) (temporal description)
Evaluation of heat exchange coefficients
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Questions to solve : Materials

Material behaviour (plasticity ; strain-stress curves) Initiation Multi axial loading Initiation - Treatment of surface finishes : roughness and strain hardening (pre loading):
How to determine their levels of influence on fatigue
Initiation - Treatment of mean stress effect (in case of large mean stress) Initiation - Damage accumulation with variable amplitude loading Initiation - Environmental effects
Transposition to on site functional situation
Validation of Fatigue initiation criteria
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Questions to solve : Materials
Propagation :
Propagation Threshold Short cracks Overload - Variable amplitude loadings Multi axial loadings
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New knowledge acquired in the recent years on some aspects of the fatigue behavior of austenitic stainless steels (304L, 316L) New open questions
examples about :
High cycle fatigue and fatigue limit
effects of surface finish effects of mean stress
Interaction between LC and HC Fatigue Environmental effects
Crack initiation and crack growth processes Illustrations from 304L or 316L fatigue data
ENSMA studies in the frame of the PhD of S. Petijean (2003) (EDF, AREVA N.P.) Y. Lehericy (2007) (AREVA N.P.) L. De Baglion (AREVA N.P.)
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Main characteristics of 304L austenitic stainless steel behaviour with regard to fatigue behaviour
a high ductility leading to fatigue limit (195-200 MPa) close to the conventional yield stress
J. C. Le Roux, 2004
Even at very low cyclic strain amplitudes in the HCF range, near the fatigue limit, 304L exhibits a significant plasticity at the macroscopic level
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INFLUENCE OF SURFACE FINISH PARAMETERS ON THE HIGH CYCLE FATIGUE BEHAVIOUR OF A 304L AUSTENITIC STAINLESS STEEL Machining or surface operations lead to microstructural and mechanical modifications: What are the effects of these modifications? What are the most significant factors that have to be taken into account? : Roughness : relevant parameters? Residual stresses: relaxation? Surface layer microstructure modification: delays or accelerates crack initiation and growth? Coupled effects: How to identify the predominating factors? The study of several surface preparation conditions permitted to establish the role of surface finish and identify the relative effect of each factor. (S. Petitjean, ENSMA 2003, EDF and AREVA (Framatome) collaboration)
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Machining conditions of some selected surface preparations (polishing, turning and grinding)
Samples Tool radius (mm)Feed rate (mm/rd)Speed (rd/mn) Depth of cut (mm) Turned T1 0,4 0,2 1600 0,2 Turned T2 0,8 0,2 1600 0,2 Turned T3 0,8 0,5 1120 0,2 Turned T4 0,8 0,7 560 0,2 Turned T5 0.8 0.7 560 0.2 SandBlasted Silica particles pres. 4 bars Ground G1 Manual 800 Grindstone tangential
And two polished sample conditions :

after fine turning (T5), a mechanical polishing using abrasive papers of grades 320, 500, 1000, 2400 and 4000 followed by diamond sprays of 3 m and 1 m is performed.
Polished P1: only the surface irregularities are suppressed; the hardness gradient is preserved
Polished P2: :the hardened layer is also taken off.
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Typical roughness profiles of some surface preparations
roughness of sample Polished P1
roughness of sample Turned T2
28 roughness (m)
28 roughness (m) 18 8 -2 -12 -22 -32

0 0,5 1 1,5 2 length (mm) 2,5 3 3,5 4
18 8 -2 -12 -22 -32
0,5
1,5
2 length (mm)
2,5
3,5
roughness of sample Turned T3

28
28 18
roughness of sample Ground G1
roughness (m)
18
roughness (m)
0 0,5 1 1,5 2 2,5 3 3,5 4
8 -2 -12 -22 -32
8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4
length (mm)
length (mm)
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Typical appearence of the surface of some 304 L cylindrical fatigue specimens
Turning T3
sandblasting
Coarse grinding
polishing
2 mm
2 mm
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With regard to fatigue, a 3D characterization of roughness is required

Turned T3
Echantillon tourn T3
28 18 8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4
Ground
rugosit de l'tat tourn 1b
samples
rugosit ru g o s it (m ( m) )
2 mm
longueur (mm) (mm) longueur
Sandblasted
28
roughness of sample G1 rugosit de ltat meul Ground cylindrique
Rugosit (m)
rugosit de l tat sabl

28
18 8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4
rugosit (m) roughness (m)
18 8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4
longueur (mm)
length (mm) longueur (mm)
- craters distributed on the specimen surface - mean dimensions: 20 m in depth, 100 m in diameter
sets of facets Lmean = 0.5 / 0.6 mm. crossed by straight grooves
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Associated gradient of hardness in the near surface layer for seven selected sample preparations
Evolution of microhardness Vickers HV25

340 microhardness HV25 320 300 280 260 240 220 200 180 0 100 200 300 depth (m)
Turned T1 Turned T2 Turned T3 Turned T4 Polished P1 Polished P2 Ground G1
400
500
600
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Surfacemicrostructuremodifications:
recristallisation, mechanical twinning, high density of dislocations, martensitic transformations
colle
600 nm
fine recristallisation, dislocations (turned, sandblast)
distorded twins and dislocations (severe turning)
twins and dislocations (turned, sandblast, polished)
phase transformations (
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Residual stress profile

- Specimens turned and ground: tensile residual stresses at the specimen surface - Specimens polished or sandblasted compressive residual stresses
Example of residual stresses profile as a function of depth ( condition Turned T3)

Profil des contraintes rsiduelles en fonction de la Evolution des contraintes rsiduelles profondeur
en fonction de la profondeur
400
Contraintes rsiduelles (MPa)
300 200 100 0 -100 -200 -300 -400 0 20 40 60 80 100 120

Profondeur (m) Tourn 1b Tourn T3
Tensile residual stresses over the first 50 m Compressive below
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Summary of the surface characterisations of the selected samples by turning, grunding, blasting and polishing
Several combinations of roughness, residual stresses, hardeness and microstructures
Condition
Ra (m) 1,6 1.94 9.6 0,34 0,34 6,3 3.65
Rt (m) 7,2 8.85 38.1 78.3 1,44 1,44 36,4 19,85
HV25
at 30 m depth
Depth of the hardened layer (m)
11 (Pa) 22 (MPa) 235 220 395 375 -190 -240 320 -770 300 260 385 630 -185 -240 480 -730
phase transform.?
T1 T2 T3 T4 Polish.P1 Polish.P2 Ground S.Blasted
323 316 337 345 318 212 345 343
250 200 250 250 150 30 200 150
Yes Yes Yes Yes
Used to identify the relative role of each factor on the fatigue properties
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- Fatigue tests under constant load amplitudes control * S-N curves in air at T = 25 C under a constant load ratio (R = 0.05) or at constant mean (mean = 0, 60, 125, 195 MPa) Seven surface preparations investigated: 3 Turned, 1 sandblasted, 1 severe ground, 2 polished
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S-N curves (f = 10 Hz, R = 0.05 and T = 25 C) of samples presenting the selected surface preparations
S-N curves (R = 0.05, T = 25 C)
240 230 220 210 200 /2 (MPa) 190 180 170 160 150 140 130 120 1,00E+05
Polished and sandblast
Turned T1 Turned T2 Turned T3 Turned T4
Turned
Polished P1 Ground G Sandblast SB
Ground
1,00E+06 Number of cycles
1,00E+07
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S-N curves (f = 10 Hz, R = -1 and T = 25 C) of samples presenting some selected surface preparations
W hler curves (R = -1, T = 25C )

280 270 260 250
/2 (MPa)
240 230 220 210 200 190 180 170 160 1,00E + 04 1,00E + 05 1,00E + 06 1,00E + 07
Turned T1 Turned T4 Polished P1 Ground G1
Num be r of cycle s
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- A strong influence of the surface finish on the fatigue limit at R = 0.05 and T = 25 C:
Ground samples ( 125 MPa) < Turned samples ( 155 MPa) < Polished samples ( 195 MPa)
-effects of the surface finish are less pronounced at R = -1

Ground samples ( 175MPa) < Polished samples ( 195 MPa)
A non-influence of the mean stress was commonly assumed for austenitic stainless steels.
Are the results influenced by performing fatigue tests under load control?
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INTHERPOL results
F. CURTIT, EDF R&D / MMC
1000 Courbe RCC-M courbe moyenne ESSAI1 Knu_min Essai4 dlardage Essai4 cote 135 mm (bross) Essai4 cote 150 mm (bross) Essai4 cote 175mm (meul) Essai2 soudure Essai2 Pmax Essai3 soudure Essai3 Pmax
Salt (MPa)
soft grinded tourn taper
polished
raw
current area
100 10000
100000
1000000
Number of cycles
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Fatigue tests at R = 0.05 (T= 25C)

maximum applied stress(MPa) elongation (%)after 600 cycles
Allongement des prouvettes cycles m = 215 MPa (max = 410 MPa) Gradual elongation observed Gradual elongation observed at = 410 MPa max f= = 10 Hz 215 MPa) and f = 10 Hz at R = 0.05 (mean
elongation at failure or at the fatigue limit (%)

11.9 (P1, failure at
289 000 cycles) -
420 410 400 380 350 330 310
10.7 9.4 8.8 5.3 3.8 2 1.4

-
420 400 380 360 340 320 300 280 260 240 220 200 180 160 140 120 100 80 60 40 20 0 0 0,009 0,018 0,027 0,036 0,045 0,054 0,063 0,072 0,081 0,09
F/S (MPa) F/S applied 0 applique 0 value In itial ap plied F /S in i (M Pa)
2.9 (T3, failure at

572 000 cycles) -
Allongement elongation elongation
280 260
1.2 (G, failure at

806 000 cycles)
0.5 (G, un-failed at

10 millions of cycles)
progressive elongation during the first cycles then accommodationspecimens present different levels of pre-deformation according to the applied load level
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Influence of the mean stress on the fatigue limit (T= 25C)
Sample preparation Polishing Sandblasting Turning Grinding
Fatigue limit (MPa) R = -1 200 190 / 200 170
Fatigue limit (MPa) R = 0.05 (elongation) 185 (5.3%) 185 (5.3%)
150 / 155 (2.5%) 125 (0.5%)
-Elongation is very low at the fatigue limit level for ground specimens. -In this case it can be concluded about the effect of the mean stress (with regard to the results at R= -1): a detrimental effect of a positive R is revealed.
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Additional results for other mean values

Diagram of Haigh
Evolution of the fatigue limit versus the applied mean stress

210 200 190 180 170 160 150 140 130 120 110 100 0 25 50 75
Fatigue limit of polished specimens is weakly modified by the application of a mean stress
po
/2 (MPa)
tat poli polished polished ground tat meul
In fact : The detrimental influence of a positive mean stress on polished specimens is compensated by the hardening induced by cycling the material under load control
100 125
150
175
200
mean stress (MPa)
Fatigue limit of ground specimens is decreased by 50 MPa when a high positive mean stress is applied
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- great influence of the surface finish at R = 0.05 and T = 25 C:

Ground samples ( 125 MPa) < Turned samples ( 155 MPa) < Polished samples ( 195 MPa)
-effects of the surface finish are less pronounced at R = -1 :

( 175 MPa/195 MPa)
Validity of the reference curve for polished specimens since established under load control and high mean stresses?
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Such results led to reconsider HCF data of austenitic stainless steels In particular the role of control parameter in fatigue tests has been reexamined : In most conditions, strain rather than stress amplitude has to be imposed in order to be more representative of the real mechanical solicitations in components
L. Vincent et al, CEA (DMN SRMA ) confirmed the detrimental effect of a mean positive stress for 304L polished specimens by performing tests under constant
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HCF behavior. Experimental approach Effect of a mean stress

controlled
Nf>5.10 cycles
6 6
controlled
Soderberg
rompu non rompu
Goodman Gerber
220 210
Nf<5.10 cycles
0.25 0.2
X4
/2 (MPa)
/2 (%)
200
X5 X2 X2 X2 X2 X2
X2
0.15
X2
X2 X2
X2 X2
190 180 170 160
0.1 0.05 0
50
100
m
150
200
250
20
40
60
m
80
100 120 140 160
(MPa)
(MPa)
d 5% lower for m = 50MPa

d 30% lower for m = 50MPa
From L. Vincent et al CEA DMN SRMA
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Related effect of a monotonic or a cyclic predeformation and the application of a positive mean stress
Results are mainly affected by the parameter of control used for the fatigue tests detrimental effect of prehardening in strain controlled tests particularly with a positive mean stress
[V. Doquet, S. Tahiri] Results recently confirmed on monotonically pre strained specimens by EDF/ECP PhDThesis
230 220
( /2) 0 applique (MPa)
Courbes de Whler des tats pr-crouis (R = 0.05, T = 25 C)
beneficial effect under stress control

[S. Petitjean, J. Mendez]
210 200 190 180 170 160 150

1,00E+05 1,00E+06
Nombre de cycles
Etat P1 pr-croui Etat M pr-croui
1,00E+07
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Relative role of roughness, surface hardening and residual stresses:

Thermal treatments were applied at different temperature levels to relax residual stresses or even to eliminate the hardened surface layer. Main results: - a poor influence of residual stresses which is explained by the relatively high plasticity level reached in 304L even for HCF - a limited effect of surface hardening . - a predominant effect of the surface topography: the acuity, length, depth and orientation of the machining grooves are the important specific features with regard to fatigue damage. Therefore, conventional roughness parameters (Ra, Rt ) are not relevant to predict the fatigue behavior of machined or surface treated samples
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Damage processes and fatigue limit
For polished specimens: no cracks are observed on non-failed specimens after 107 cycles.
Fatigue limit is in this case clearly associated with non initiation conditions.
In ground specimens the number of cycles to form a crack of the size of the groove is very similar to the number of cycles needed to propagate it to failure.
Fatigue limit associated with the effective K threshold obtained for long cracks.
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Crack growth of natural short cracks in turned or ground specimens (R = 0.05) Initiation on two connected machining defaults (turned sample)
Evolution of crak length with the number of cycles

2500
2000 longueur en surface (m)
Etat T5 smax = 330 MPa Etat M - smax = 290 MPa
1500
multi cracking
1000
fissures de fatigue
500
Amorages multiples et coalescence

0 0 100000 200000 300000 400000 500000 Nombre de cycles
Multiple cracking and coalescence processes (ground specimen)
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Crack propagation curves R = 0.1 ( CT samples) and R = 0.05 (cylindrical specimens) - R = 0.05 - R = 0.05 - R = 0.1 (cylindrical specimen turned T3 (max = 330 MPa) (cylindrical specimen : ground - max = 290 MPa) (CT specimen) (C. Sarrazin-Baudoux et J. Petit - 2001)
Crack propagation curves of 304L at RT
1,E-03 1 10 100 R = 0,1 CT nominal
1,E-04
Curves established for max = 290 MPa and max = 330 MPa are superimposed to the da/dN-Keffective curve for long cracks But K is not the accurate parameter when plasticity is high
R=0,1-
da/dN (mm/cycle)
1,E-05
CTeffective
1,E-06
R=0,05t Turned T5 cycled under 330 MPa R=0,05 Ground cycled 290 MPa
1,E-07
1,E-08 K (MPa.rac(m)) K (MPa. m )
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Influence of a LCF pre-damage on the 304L stainless steel fatigue limit

Needs: Control the residual HCF properties of ASS in presence of a fatigue predamage due to the occurrence of solicitations of high amplitude (stops and starts, power increase events) Evaluate the effect of the surface finish Objectives and Procedures
Damage accumulation In the HCF range
Study of the 304L behavior loaded under LCF conditions Cyclic behavior LCF induced damage
typically t/2 = 0,3%
Fatigue limit of pre-damaged samples Influence of surface finish Effect of mean stress Relevant physical or mechanical parameters for the prediction of the fatigue life.
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Test conditions :
t/2 = 0,3% f=0,333 Hz
R=-1 T=25 C
(polished specimens with hardened surface layer)
4 1 2 3 NF = 25 000 cycles
3750 cycles
7500 cycles
Crack initiation 4000 cycles

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N = 7 500 cycles (30%de NR) (three different specimens)
Scattering associated with the crack length at the initiation
Initiation at twin boundaries : 80 m < L0 < 150 m
The hardened layer delays crack initiation but accelerates crack growth
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Polished specimens with hard surface layer(200 m)
Crack growth described by a Tomkins et Wareign type law: dL/dNp = C . (p/2) . L L = L0 . exp (C . (p/2) . Np)
Material constants
with Np=N - Na et Na ~ 4 000 cycles
Identification of C and from experimental data :
Ln (L/L0)
L0 = 80 m p/2 = 0,175 % Lf = 4 500 m
C = 6,5 .10-3 =2
L = L0 . exp (6,5.10-3 . (p/2)2 . Np)
50 18-20 Novembre EDF / MAI - ENSMA Poitiers Nombre de 2008 cycles en propagation
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Effect of surface grinding on LCF resistance
polished severe grinding spherical grinding
Polished NF 25 000 cycles Severe grinding NF 7 500 cycles Spherical grinding NF 20 000 cycles
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304L surface, ground with a spherical grindstone
The groove orientations are randomly distributed on the surface. The size of grooves, perpendicular to the loading direction in which cracks preferentially initiate, are in this case similar to the microstructure dimensions.
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Effect of a severe grinding on crack initiation and growth N = 1 000 cycles
The main crack already reaches 662 m surface length and 49 m in depth multi-cracking initiation along one straigth groove
Pre cycling 1000 cycles 1000 cycles 1000 cycles 1000 cycles Surface length (m) 510 795 531 662 depth (m) 42 26 78 49
Weak scattering on the main crack length on four specimens
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precycling
Crack initiation under LCF
Decrease of the fatigue limit
Even if the initiation of a crack is not achieved, precycling can produce a small decrease in the fatigue limit of the 304L due to induced cyclic softening
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Fatigue limit predicted by the K effective threshold approach
Fatigue limit MPa
K=Y..(a)1/2
D =
K th ,eff Y a
Kyh, eff = 2,1 0,4 MPa.m-1/2
Initial crack depth m
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Mechanical parameters controlling crack growth

K effective approch 40m <a < 40m approch 40m <a < 40m
Tests under mean= 0 MPa Tests under mean= 125 MPa
For full tension-compression Tests mean= 0 MPa
/2 > 190 MPa /2 < 180 MPa
Crack growth controlled by p/2 Crack growth controlled by Keff Plasticity threshold 180 MPa
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Other subjects
LCF behavior and damage mechanisms in LWR environment Role of temperature Role of environment Always in relation with acceptable surface preparation for industrial components
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Environmental effects on fatigue behavior of Reactor Materials in LWR environment.
Many studies have shown that fatigue lives of reactors materials are reduced in LWR environment when compared to those obtained in air at high temperature.
For austenitic stainless steels, fatigue lives in LWR environment depend on 3 key parameters: - Strain rate - Dissolved Oxygen content - Temperature These parameters are taken into account to evaluate fatigue life correction factor Fen for austenitic stainless steels in reactor coolant environment (expression based on ANL model): *Fen = Nair(RT) / Neau(LWR) =
*[Chopra et al.; 2007; NUREG/CR-6909] 58 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers
Effects of temperature
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The LWR environment effect is enhanced at high temperature. LCF test results obtained on a 304L SS in PWR environment and in Air, at two temperatures 150 C and 300 C: fatigue life in water, is strongly reduced at 300 C and not so much at 150 C even for some LCF tests performed at high strain rates
[Solomon, Amzallag et al.; 2004; PVP Seville] 59 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers
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Effects of environment
For Austenitic Stainless Steel, comparison of LCF test results obtained in air at 300 C and in deaerated water at high temperature (sa me strain rate and strain amplitude) : - Same cyclic stress behavior. - Decreasing fatigue life in water environment.
[Cho et al.; 2008; Materials Science and Engineering (248-256)]
Effects of strain rate
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[Cho et al.; 2008; Materials Science and Engineering (248-256)]
[Chopra et al.; 2007; NUREG/CR-6909]
Austenitic stainless steels exhibit Dynamic Strain Aging in the temperature range of 200 to 800 C. Detrimental effect of decreasing strain rate in C : deaerated water at high temperature or in air at 300 - Increases cyclic stress behavior. - Decreases fatigue life.
Effects of strain rate

For any strain amplitude, in high temperature deaerated water, reduction of fatigue life increases with decreasing strain rate.
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**304L, Air 300 C 0.4%/s & 0.01%/s
x x
In air, steels, and particularly, austenitic stainless steels are sensitive to Dynamic Strain Aging in the temperature range of 200 to 800 C.
[2]
[Cho et al.; 2008; Materials Science and Engineering (248-256)] **[De Baglion, Mendez et al.; 2008; PhD AREVA NP in progress]
*Saturation of environmental effect in High temperature water at : - 0.0004%/s for 304L SS. - 0.004%/s for 316L SS.
*[Chopra et al.; 2007; NUREG/CR-6909]
So, decreasing fatigue life in LWR environment is enhanced by low strain rate.
Need for a better consideration of the material behavior in air at high temperature
[Chopra et al.; 2007; NUREG/CR-6909] 62 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers
Combined effects of PWR environment and surface finish for LCF test performed using a complex representative loading signal
Tests with a more representative signal : SIS Variable strain rates, as close as possible to transients applied to Safety Injection nozzles. The strain history corresponds to a cold shock followed by a hot thermal shock. There are 2 types of signals : Short SIS (840s) & Long SIS (2400s)
[Le Duff, Lefranois, Vernot et al.; AREVA NP; 2008; PVP Chicago]
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In PWR water, for a representative SIS loading signal and ground specimens, experimental Fen are much lower than expected Fen penalty factors.
[Le Duff, Lefranois, Vernot et al.; AREVA NP; 2008; PVP Chicago]
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Current research work
Determining the mechanisms of crack initiation and growth in vacuum, air and PWR environment taking account for representative loading signals and temperature effects
Current research AREVA NP ENSMA L. de Baglion PhD Thesis
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Other new challenges for the next years

Determine crack initiation and crack growth at the micro and meso scales (scale of microstructure) for austenitic 304L or 316L stainless steels taking account for surface finishes
Ex: role of the crystallographic texture
200 m
At a macroscopic scale
Global texture of 316L : -RX analysis - EBSD analysis
Flat part
23% <111> 16% <100> 6% <110> 55% <other> (essentially <112>)
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At a microscopic (one grain) or mesoscopic scale (several grains) Identification of active slip systems and crack initiation conditions through EBSD analysis
Schmid factor:
] 10 )[1 11 (-1 04 A6 =1 A6 = 90 6 DG
] 10 1 42 [ ) = 11 6 1DG ( D6 64 = D6
D4
(1-1 1)[101 4=5 ] 3 D
{111} <110> = (nPG . ) ( dg . ) {111} <110> = cos . cos

surface
G4
e ent n ds m Plag lis e
dir gli ecti sse on me d e nt
orientation PG
10 m
Of slip systems with regard to the free surface :
[11 0]
316L -20C - p
/2=2.10-3
- 5000 cycles - Air
cos PG = nPG . nsurf.
=4
[11 0]
n s urf.
s urfac e
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LMPM
First stages of crack propagation

Transgranular crack initiation transgranular propagation
Crack initiation in twin intergranular propagation
propagation
Site damorage transgranulaire
Site damorage joint de macle
D4 =0,395 =55 [324] A2/D4=0,86
B2 =0,461 =52 =42
A2 =0,341
( [40 55], [45 60])
- =0.461 > 0.41 - =52 et =42
- =55 - Slip activity in both sides of the grain boundary
The local conditions that favor crack initiation are also favorable to their propagation through the surrounding grains
LMPM
ANR program : AFGRAP

Fatigue crack initiation in a grain of a polycrystalline aggregate and propagation in surrounding grains
Objectives:
Modeling of the fatigue crack initiation and of the first stages of propagation in the 316L (influence of surface properties)
- Crack initiation criterion : at the scale of the grain taking into account slip activity - Crack propagation criterion : local configuration of grain boundary and of surrounding grains
Developments based on numerical and experimental tools : - Discrete Dislocation Dynamics simulation - Crystalline Plasticity theory and calculation applied to polycrystalline aggregates - Experimental identification by micro structural analysis at different scales Industrial and academic partners : EDF R&D, AREVA NP, CEA (SRMA), ARMINES (ENSMP-ParisTech), LMSSMat of ECP (Paris), SIMAP and SYMME of INPG (Grenoble), LMPM of ENSMA (Poitiers) coupling
LMPM
Example of numerical simulation of stress localisation induced by roughness
Virgin material
Pre-strained polished material
Pre-strained and rough surface
LMPM
THANK YOU FOR YOUR ATTENTION
LMPM
Questions to solve
Multi-frequential Variable amplitude Loading
Industrial surface finish
Wall thickness Stress gradient
Mean static loading

(pressure and piping constraints)
Bi-axial Stress State Welds

(Geometric singularities, Residual Stresses HAZ)
Crack network
(interaction between cracks)
Multi disciplinary
LMPM

Fatigue - in - LWRs - Va Inox 304 PDF

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FATIGUE in LWRs

International Conference on Plants Materials Degradation November 18-20 , 2008

J. MENDEZ (LMPM-ENSMA) J.M. STEPHAN (EDF)

2 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Fatigue is an ageing process !

3 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Fatigue is cited in life extension of NPPs :

4 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Origin of Fatigue in NPPs

5 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Solicitations and Materials

Solicitations and Materials

Solicitations and Materials

Solicitations and Materials

9 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Solicitations and Materials

10 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Solicitations and Materials

Solicitations and Materials

12 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Codes and Rules

can have wide implications in industry

13 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Codes and Rules

WWER PNAE Code

Fatigue : Main needs

15 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Research at the micro and meso level : Dislocations, Aggregates

16 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Questions to solve : Thermal Hydraulics

Evaluation of heat exchange coefficients

17 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Questions to solve : Materials

Validation of Fatigue initiation criteria

18 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Questions to solve : Materials

19 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Interaction between LC and HC Fatigue Environmental effects

20 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

22 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

And two polished sample conditions :

Typical roughness profiles of some surface preparations

roughness of sample Polished P1

roughness of sample Turned T2

28 roughness (m) 18 8 -2 -12 -22 -32

18 8 -2 -12 -22 -32

roughness of sample Turned T3

roughness of sample Ground G1

8 -2 -12 -22 -32

8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4

24 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Typical appearence of the surface of some 304 L cylindrical fatigue specimens

With regard to fatigue, a 3D characterization of roughness is required

longueur (mm) (mm) longueur

roughness of sample G1 rugosit de ltat meul Ground cylindrique

rugosit de l tat sabl

18 8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4

rugosit (m) roughness (m)

18 8 -2 -12 -22 -32 0 0,5 1 1,5 2 2,5 3 3,5 4

sets of facets Lmean = 0.5 / 0.6 mm. crossed by straight grooves

26 18-20 Novembre 2008 EDF / MAI - ENSMA Poitiers

Evolution of microhardness Vickers HV25