A Review on High Temperature Rupture Mechanisms of Dissimilar Metal Welded Joints for the USC Thermal Power Units

doi:10.3901/JME.2022.24.058

Abstract

Abstract: There are numerous dissimilar metal welded joints (DMWJs) composed of ferrite heat-resistant steel and austenitic heat-resistant steel/nickel-based alloy in the boiler heating surface pipe system of ultra-supercritical (USC) thermal power units in China. The productive practices demonstrate that most of the DMWJs have early failure after service for 70 000-100 000 hours, and their service life is far less than the design life of 30 years or 200 000 hours. The frequent occurrence of early cracking accidents of DMWJs not only causes great harm to the safe operation of the unit, but also suffers great economic losses and negative social effects to the power generation enterprises. Meanwhile, it also reflects that the current understanding about weldability of dissimilar metals, especially the high temperature service performance of DMWJs, is still insufficient. In order to further reveal the early failure reasons of DMWJs, this work reviewed and summarized the research results of high temperature mechanical properties of 9-12%Cr/Nickel superalloy and 9-12% Cr/Austenitic dissimilar welded joints under high temperature creep and high temperature fatigue around China and other countries in the past two decades. The effects of various factors on the high temperature failure modes and failure characteristics of DMWJs were summarized through the ambient temperature, loading stress, thermodynamic characteristics, welding residual stress, microstructural evolution, et al. The fracture mechanisms of DMWJs under high temperature creep and fatigue conditions were expounded in detail, and it was also introduced a considerable of currently popular physical models about high temperature fracture damage and their development and application. Finally, it was proposed that two effective methods to improve the high temperature mechanical properties of DMWJs, and prospected for the relative researching trend in future.

Key words: dissimilar metal welded joints, early failure, high-temperature creep, high-temperature fatigue, facture mechanisms

CLC Number:

TG407

KANG Ju, WANG Qibing, WANG Zhichun, HAN Zhewen, ZUO Yue, ZHANG Hua, JIAO Xiangdong. A Review on High Temperature Rupture Mechanisms of Dissimilar Metal Welded Joints for the USC Thermal Power Units[J]. Journal of Mechanical Engineering, 2022, 58(24): 58-83.

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