Project No: FE0005859
Performer: General Electric Company


Contacts

Federal Project Manager: Cedro, Vito: Vito.Cedro@netl.doe.gov
Technology Manager: Maley, Susan: Susan.Maley@netl.doe.gov
Principal Investigator: Chen Shen: Shen@research.ge.com

Duration
Award Date:  10/01/2010
Project Date:  01/20/2014

Cost
DOE Share: $1,199,940.00
Performer Share: $299,988.00
Total Award Value: $1,499,928.00

Performer website: General Electric Company - http://www.ge.com

Crosscutting Research - Plant Optimization Technologies

Modeling Creep-Fatigue-Environment Interactions in Stream Turbine Rotor Materials for Advanced Ultras

Project Description

GE Global Research, GE Energy, and the University of Pennsylvania will model creep-fatigue-environment interactions in steam turbine rotor materials for advanced ultra supercritical coal power plants. The work will demonstrate computational algorithms for alloy property predictions and to determine and model key mechanisms contributing to the damages of creep-fatigue-environment interactions.



Program Background and Project Benefits

This project will enable more accurate prediction of long service life of advanced alloys for AUSC power plants These advancements will enable faster materials design and implementation and better producibility of large scale components. Improvement to high-temperature advanced-materials will promote the development of advanced power plant designs that can operate at higher temperatures and pressures, leading to higher efficiency and operational flexibility and resulting in lower capital and operating costs.


Accomplishments

The research team is developing a fundamental understanding of the fatigue failure mechanisms in the nickel-based Haynes 282 superalloy, including an understanding of the fatigue threshold of the superalloy. GE has started work on a mesoscale microstructure-based crack model. Atomic level modeling has been performed on grain boundary chemistry and structure with a focus on oxygen energetics and mobility and its impact on oxide formation.

The project team has investigated the crack growth response of Haynes 282 as a function of test temperature, cyclic period, environment, and the applied delta K value. Both creep-fatigue and environmental-fatigue interactions were found to be operative depending upon test temperature. A phase field model framework is being built to treat mesoscale crack growth, polycrystalline microstructure, oxygen diffusion, and oxidation concurrently. This initial work demonstrated the ability to treat stress fields of cracks in an elastically anisotropic and inhomogeneous polycrystal using the phase field microelasticity theory. The project team has also developed a model for the creep behavior of Haynes 282 as a function of time, temperature, and applied stress. This model shows good agreement with experimental creep data over the range of temperatures and applied stresses that would be encountered in A-USC applications. At a larger length scale the project team has also started to develop a FORTRAN-based confined crack tip plasticity model based on the evolution equations for the near crack tip plastic deformation response. The team calibrated the model against finite element modeling results of near crack tip plasticity.