Creep and High Temperature Failure: Outline

Creep and High Temperature Failure
Materials often placed in service at elevated temperatures and static

mechanical stresses (turbine rotors in jet engines and steam generators
that experience centrifugal stresses, and high-pressure steam lines).
Outline
Creep and high temperature failure
Creep testing
Factors affecting creep
Stress rupture life time behaviour
Creep mechanisms
Example
Materials for high creep resistance
- Refractory metals
- Superalloys
Such deformation is termed creep.

Observed in .. materials types;
For metals becomes important at temperatures >
Amorphous polymers, which include plastics and rubbers, very
sensitive to creep deformation.
Typical creep test: - subjecting a specimen to load/stress at
. temperature; - measure deformation or strain and - plot as
function of elapsed time.
Most tests are constant load type, which yield information of an
engineering nature; constant stress tests are employed to provide a
better understanding of the mechanisms of creep.
Dr. M. Medraj
Mech. Eng. Dept. - Concordia University
MECH 321 lecture 12/1
Dr. M. Medraj
Creep and High Temperature Failure
Constant load applied at constant high temperature

deformation as a function of time ( vs. t)
three stages of creep:
stage I (primary creep)
continuously diminishing creep rate due to
Creep Curve
Stage II (secondary steady-state
creep)
- Constant rate or plot becomes
linear
- longest and . stage

Balance between competing
strain hardening and recovery
(softening) of the material
Stage III (tertiary creep)

accelerated rate leading to creep
rupture or failure
intergranular cracking and/or
formation of voids and cavities
Dr. M. Medraj
Dr. M. Medraj
Creep Testing and Steady-State Creep Rate
Stress and Temperature Effects
Performed in uniaxial tension with specimens of similar

geometry to tensile testing
brittle materials: uniaxial compression with cylindrical samples
(flaw effect minimized)
Creep is observed > 0.4Tm

below 0.4Tm, no plastic
strain with time.
If stress Or temperature is
increased:
- the creep rate
- instantaneous strain
..
- steady-state creep rate
..
- creep rupture lifetime
Creep Data
most important parameter is the steady-state creep rate (/t)
used as a design parameter in structures which are expected to
last a long time (minimum strain) e.g. electric power and
chemical plants
creep rupture lifetime (tr) is more important in design for short
lifetimes, e.g. gas turbine engine blades (F-18 turbine blade)
- creep test continued until failure (creep rupture tests)
Dr. M. Medraj
Dr. M. Medraj
Most common creep data representation is a plot of log versus log tr

(creep rupture lifetime)
linear relationship is found for data plotted at different temperatures
these data can be used in design of components
Stress-Strain-Time
Stress-Rupture Lifetime Behaviour
Creep strength: stress at a given temperature which produces a certain

steady state creep rate e.g 0.00001%/hr (0.01%/1,000hr)
Rupture Strength: stress at a given temperature to produce a certain life
to rupture, usually 1,000, 10,000 or 100,000 hr.
Numbers are %Area
Reduction at failure
Note: Not all

materials show such
nice straight lines.
What is the stress

required to produce
fixed strain?
(e.g. 0.5%) in fixed
time (e.g. 1000 hrs)
Figure 13-18 (Dieter) Deformation-time curves
at 1300F (705oC) for 16-25-6 alloy.
Stress vs. rupture lifetime for a nickel alloy at different temp.

Dr. M. Medraj
Dr. M. Medraj
Influence of Temperature
Stress-Steady State Creep Rate Behaviour
Diffusion is an exponential function of temperature (thermally

activated process)
inclusion of temperature universal creep equation:
Empirical relationship exists between

steady-state creep rate and applied stress
& = K1 n
s = K n exp
Qc
RT
Where K1 and n are material

constants
Where K2 is a constant and Qc is the activation energy for creep
& s versus (log-log

scale) yields a linear curve
slope is 1/n
nickel alloy at different temperatures

Dr. M. Medraj
Experimental value of n can be used to predict creep strain rate at

different working conditions
activation energy for creep, Qc, can be obtained from plots of log
creep rate versus 1/T
can relate Qc to the activation for diffusion and correlate it to diffusion
processes
this might be expected since creep involves mass transfer or diffusion
Dr. M. Medraj
Influence of Temperature
Creep and Dislocation Movements
line shows 1:1 correlation
Activation energy for creep in

metals at high temp. is equal to
that for self-diffusion (i.e. vacancy
transport - dislocation climb).
If vacancies move faster - metal
creeps faster.
Other mechanisms are possible;
grain boundary sliding
..
Dr. M. Medraj
Figure 6.57 Dislocations can (a) when atoms leave the dislocation line
to create interstitials or to fill vacancies or (b) when atoms are attached to the
dislocation line by creating vacancies or eliminating interstitials. From The
Figure 13-13 Correlation between
activation energies for high-temperature
creep and self-diffusion.
science and Engineering of Materials 4th edition by D.R. Askeland and P.P. Phule.
If vacancies move faster - metal creeps faster

Dr. M. Medraj
Superplasticity
Superplastic Forming with Diffusion Bonding
Superplasticity is the ability of a material to withstand very large

amounts of elongation without the occurrence of necking
Superplastic Forming can be combined
with to produce a
number of complex SPF/DB structures.
This property is related to a

predominant mechanism of
deformation : ..
sliding
Consequently, it is promoted by
a fine microstructure (typically a
mean grain size less than about
twenty microns is required in the
case of metallic alloys).
This property has been used
for a long time as a forming
technique for components with
a particularly complex shape
Dr. M. Medraj
SPF/DB parts are produced by joining

several sheets in a specific pattern and then
superplastically expanding the sheets to
produce an integrally-stiffened structure.
Superplastic deformation of an Al alloy
Movement of grains during superplastic

deformation of a Pb-Sn alloy
Dr. M. Medraj
Suggested creep mechanisms
Data Extrapolation-Larson-Miller parameter
(a) Viscous creep for

amorphous solids; diffusional
and dislocation creeps (b and c)
in crystalline solids.
Vacancy diffusion
through bulk (NabarroHerring Creep) or
along grain boundaries
(Coble creep). Hence
larger grains or single
grain/crystal .
(c) Dislocation creep still

relies on vacancy diffusion.
Impractical to collect data over long

times, e.g several years
solution: perform creep rupture tests at
higher temperatures under same stress
for shorter times
extrapolate for service conditions
Larson-Miller parameter:
P1 = T(C + log tr)
- C is a constant (~20)
- T is temperature (K)
- tr is the creep rupture life (hours)
plot log versus log L-M parameter
i.e. for a given material at some specific stress level, the time-to-rupture will vary with
temperature such that P1 remains ..... Often plotted as Log stress vs Log P1.
Dr. M. Medraj
Dr. M. Medraj
Data Extrapolation-Larson-Miller parameter
Example
Table 13.3 (Dieter) Time compression operating conditions

based on Larson-Miller parameter. C = 20
Using the LarsonMiller data for S-590 iron shown in the figure
below, predict the time to rupture for a component that is subjected
to a stress of 140 MPa (20,000 psi) at 800C (1073 K).
long times at low

temperatures.
much shorter
times at higher
temperatures.
As long as still the same creep mechanism!

Note: not all materials have good L-M Parameter plots. Other
extrapolation methods can be used (e.g. Sherby-Dorn Parameter).
Dr. M. Medraj
Dr. M. Medraj
Refractory metals
Materials for High Temperature Creep Resistance
have extremely high melting temperatures
Generally, factors for better creep resistance include:
niobium (Nb )
molybdenum (Mo )
tungsten (W)
tantalum (Ta)
9 . melting temperature
9 . elastic modulus
9 . grain size (small grains allow more grain boundary sliding)
2468C
2617
3410C . melting metal
2996C
due to very strong interatomic bonding and also have

- large elastic moduli
- high strengths & hardnesses, (ambient & elevated temperatures).
Metallic materials commonly used for high temperature service include:

Stainless steels - Alloys based on Fe + carbon + Chromium (+
Nickel/Manganeseetc)
- Chromium provides oxidation resistance (1000oC) - gas turbines, steam
boilers etc
Refractory metals
Superalloys
Dr. M. Medraj
9 Tantalum and molybdenum are often alloyed with stainless steel to improve
its corrosion resistance.
9 Molybdenum alloys - extrusion dies and structural parts in space vehicles;
9 Tungsten alloys - incandescent light filaments, x-ray tubes, and welding
electrodes.
9 Tantalum is immune to by virtually all environments at
temperatures below 150C, and is frequently used in applications requiring
such a corrosion-resistant material.
Dr. M. Medraj
Superalloys
Superalloys
Superlative combinations of properties.

Most are used in aircraft turbine components, (exposure
exposure to severely oxidizing
environments and high temperatures for reasonable time periods).
periods
Mechanical integrity under these conditions is critical; density is important centrifugal stresses are diminished in rotating members when the density is
.
nickel and cobalt superalloys are and

strengthened to maximise their creep resistance
superalloys are also grown as single crystals to eliminate .
thus improving the creep behaviour.
Classified according to predominant metal in the alloy,

9 Cobalt + alloying elements
9 Iron + alloying elements
9 Nickel + alloying elements
alloying elements include the refractory metals (Nb, Mo, W, Ta), Cr and Ti.
In addition to turbine applications, these alloys are utilized in nuclear reactors
and petrochemical equipment.
E.g. Alloy X : (bal Ni) + Cr 20.5-23.0, Fe 17.0-20.0, Co 0.5--2.5, Mo 8.0-10.0, W
0.2-1.0, Ti 0.15, Al 0.50, C 0.05-0.15, Mn 1.0, Si 1.0, B 0.008, Cu 0.5
produced by directional solidification
high temperature petro-chemical alloy

Dr. M. Medraj
Next time:
Review for the midterm exam
Dr. M. Medraj
Dr. M. Medraj

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What are the three stages of creep?

What are the three stages of creep?

What factors affect the creep rate?

What factors affect the creep rate?

Creep and High Temperature Failure

Materials often placed in service at elevated temperatures and static

Such deformation is termed creep.

Mech. Eng. Dept. - Concordia University

MECH 321 lecture 12/1