International Journal of Pressure Vessels and Piping最新文献_第8页

Microstructural evolution, creep damage mechanism and failure risk of P92 steel welded joints after long-term service P92钢焊接接头长期使用后的组织演变、蠕变损伤机理及失效风险

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-10-07 DOI: 10.1016/j.ijpvp.2025.105677

Lipeng Cai , Lei Zhao , Kai Song , Lianyong Xu , Yongdian Han , Kangda Hao , Qingfeng Wang , Derui Guo

To ensure safe and reliable operation of high-temperature power plant components, it is crucial to evaluate the failure risk of P92 steel welded joints after long-term service. This study systematically investigated microstructural evolution and creep damage mechanisms using a multi technique characterization approach to analyze weld metal (WM), coarse grained heat-affected zone (CGHAZ), fine grained heat-affected zone (FGHAZ), and base metal (BM). Results revealed pronounced softening in the FGHAZ, with microhardness declining to 175 HV10, while repair welding partially restored microstructure and hardness in WM and CGHAZ. Degradation in FGHAZ, including precipitate coarsening and lath structure loss, remained largely irreversible. Creep cavities preferentially nucleated at δ-ferrite, grain boundary triple junctions, and coarse M₂₃C₆ and Laves phases. TEM observations showed extensive dislocation entanglement and slip around coarse precipitates, facilitating microcrack initiation, whereas MX carbonitrides remained stable. EBSD analysis indicated severe microstructural degradation in FGHAZ, with reduced lath boundaries and kernel average misorientation, and increased fractions of recrystallized grains and subgrains, contributing to localized softening and elevated creep susceptibility. Based on these findings, a creep damage model governed by microstructural degradation and abnormal δ-ferrite distribution was proposed. Overall, the study identified δ-ferrite and coarse precipitates as primary damage nucleation sites, providing quantitative microstructural metrics to guide failure risk assessment and life prediction of P92 welded joints after long-term service.

为保证电厂高温部件安全可靠运行，对P92钢焊接接头长期使用后的失效风险进行评估至关重要。本研究采用多技术表征方法系统地研究了焊缝金属（WM）、粗晶热影响区（chaz）、细晶热影响区（FGHAZ）和母材（BM）的显微组织演变和蠕变损伤机制。结果表明，FGHAZ出现明显的软化，显微硬度下降至175 HV10，而补焊部分恢复了WM和CGHAZ的显微组织和硬度。FGHAZ中的降解，包括沉淀粗化和板条结构损失，在很大程度上仍然是不可逆的。蠕变空洞优先在δ-铁素体、晶界三重结、粗M23C6和Laves相处成核。TEM观察显示，粗相周围存在广泛的位错纠缠和滑移，有利于微裂纹的萌生，而MX碳氮化物则保持稳定。EBSD分析表明，FGHAZ中存在严重的微观结构退化，板条边界和核平均取向错误减少，再结晶晶粒和亚晶粒的比例增加，导致局部软化和蠕变敏感性升高。在此基础上，提出了以微观组织退化和δ-铁氧体异常分布为主导的蠕变损伤模型。总体而言，研究确定δ-铁素体和粗相是主要的损伤成核部位，为指导P92焊接接头长期使用后失效风险评估和寿命预测提供了定量的显微组织指标。

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引用次数: 0

Simplified formulation of the Beremin model's industrial variation for pressurized thermal shocks 加压热冲击Beremin模型工业变化的简化公式

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-10-04 DOI: 10.1016/j.ijpvp.2025.105674

S. Chapuliot, C. Sénac

This paper presents the development of a semi-analytical version of the industrial variation of the Beremin model for brittle fracture exclusion. Such an approximate expression is needed for two branches of safety analysis: on the one hand, for probabilistic studies which cover a large set of material, loadings, and geometrical conditions, and on the other hand, for the severity ranking of thermomechanical transients in deterministic studies. First, this article offers a short synthesis on the industrial variation of the Beremin model. Then, the physical foundations of the semi-analytical formulation are detailed. Indeed, the latter is based on analytical developments of the stress field at the tip of a crack combined with simplifying assumptions that are checked on fracture mechanics specimen of various geometry and on reactor pressure vessels’ surface defects. Owing to these prior analyses, a simple formulation relying on three geometrical parameters and one material-dependent parameter is finally proposed. The accuracy of this semi-analytical formulation is established by a comparison to the detailed industrial variation of the Beremin model on two complex industrial applications.

本文提出了Beremin脆性断裂排除模型工业变化的半解析版本的发展。安全分析的两个分支需要这样的近似表达式：一方面，用于涵盖大量材料、载荷和几何条件的概率研究，另一方面，用于确定性研究中热机械瞬态的严重程度排序。首先，本文对Beremin模型的产业变化进行了简短的综合。然后，详细介绍了半解析公式的物理基础。实际上，后者是基于裂纹尖端应力场的分析发展，并结合了各种几何形状的断裂力学试样和反应堆压力容器表面缺陷的简化假设。基于这些先前的分析，最后提出了一个依赖于三个几何参数和一个材料相关参数的简单公式。通过与Beremin模型在两个复杂工业应用中的详细工业变化进行比较，建立了这种半解析公式的准确性。

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引用次数: 0

Investigation of corrosion effects on the performance of underground steel pipelines under blast loading and a solution for retrofitting 爆炸荷载作用下地下钢管道腐蚀对性能的影响及改造对策研究

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-10-04 DOI: 10.1016/j.ijpvp.2025.105669

Mohammad Tabiee, Alireza Khaloo

Pipelines have long been used for the transportation of strategic fluids worldwide. However, exposure to environmental conditions and extended service life significantly increase the risk of corrosion, which in turn reduces the structural strength of pipelines against external loads, particularly blast loading. This study numerically investigates the behavior of pipelines with internal and external corrosion subjected to blast loads. The use of fiber-reinforced polymers (FRP) is also examined as a retrofitting technique to enhance the blast resistance of corroded pipelines. A parametric study was performed to assess the influence of corrosion geometry and FRP thickness on the structural response. The results demonstrate that FRP effectively improves the blast performance of corroded pipelines under various conditions. Specifically, employing CFRP with half the pipe thickness reduces the maximum stress by over 30 % and decreases the maximum longitudinal and hoop strains by more than 55 % in certain cases. This study integrates blast–corrosion interaction with FRP retrofitting strategies within a validated Coupled Eulerian–Lagrangian (CEL) framework, providing a novel approach to assessing the dynamic performance of corroded pipelines. The findings offer quantitative engineering guidance for the protection and strengthening of buried pipelines subjected to extreme explosion scenarios.

长期以来，管道一直被用于全球战略流体的运输。然而，暴露在环境条件下和延长的使用寿命大大增加了腐蚀的风险，这反过来又降低了管道抵抗外部载荷（特别是爆炸载荷）的结构强度。本文对管道内外腐蚀在爆炸荷载作用下的性能进行了数值研究。纤维增强聚合物（FRP）的使用也被研究作为一种改造技术，以提高腐蚀管道的抗爆炸能力。进行了一项参数研究，以评估腐蚀几何形状和FRP厚度对结构响应的影响。结果表明，FRP能有效改善腐蚀管道在各种工况下的爆破性能。具体而言，在某些情况下，使用管道厚度为管道厚度一半的CFRP可将最大应力降低30%以上，并将最大纵向和环向应变降低55%以上。该研究将爆炸-腐蚀相互作用与FRP改造策略整合在一个经过验证的耦合欧拉-拉格朗日（CEL）框架内，为评估腐蚀管道的动态性能提供了一种新的方法。研究结果为极端爆炸工况下埋地管道的保护和加固提供了定量的工程指导。

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引用次数: 0

Numerical and experimental analysis of welding parameters on residual stress in stainless steel 304L using ultrasonic methods 用超声方法对304L不锈钢焊接参数对残余应力的影响进行数值和实验分析

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-10-01 DOI: 10.1016/j.ijpvp.2025.105665

Amirhossein Rasfijani, Alireza Fadaei, Mohammadjavad Maghsoudi, Mehdi Ahmadi Najafabadi

Residual stresses generated by the welding process have a significant impact on the structural performance and service life of components. In this study, the effects of welding speed and current on longitudinal residual stresses in AISI 304L austenitic stainless steel (SS 304L) were investigated using both experimental and numerical approaches. Residual stresses were measured at a depth of 1.5 mm using longitudinal critically refracted (Lcr) ultrasonic waves, and the acoustoelastic coefficients of the base metal and weld metal were determined through uniaxial tensile testing. Numerical simulations of the welding process were conducted using ABAQUS software.

The results showed that residual stresses in the weld metal region are tensile and gradually shift toward compressive values with increasing distance from the weld center. Increasing the welding speed reduced the magnitude of residual stresses, whereas increasing the current led to an increase in residual stress levels. A comparison between the numerical simulation and experimental ultrasonic measurements revealed an average discrepancy of 27 MPa in the weld metal region (equivalent to 15 %) and 10 MPa in the base metal region (equivalent to 12 %). The maximum observed difference between the numerical and experimental results was 40 MPa at the weld line and 39 MPa in the base metal. The findings of this study demonstrate the effectiveness of combining ultrasonic testing and finite element simulation in analyzing and optimizing welding parameters and predicting residual stress distributions.

焊接过程中产生的残余应力对构件的结构性能和使用寿命有重大影响。采用实验和数值方法研究了焊接速度和电流对AISI 304L奥氏体不锈钢（SS 304L）纵向残余应力的影响。利用纵向临界折射（Lcr）超声波测量1.5 mm深度处的残余应力，并通过单轴拉伸测试确定母材和焊缝金属的声弹性系数。利用ABAQUS软件对焊接过程进行了数值模拟。结果表明：随着离焊缝中心距离的增加，焊缝金属区的残余应力以拉伸为主，逐渐向压缩方向转移；提高焊接速度可减小残余应力的大小，而增加焊接电流可增大残余应力的大小。数值模拟与实验超声测量结果的对比表明，焊缝金属区域的平均差异为27 MPa（相当于15%），母材区域的平均差异为10 MPa（相当于12%）。观察到的数值与实验结果之间的最大差异为焊缝处40 MPa，母材处39 MPa。研究结果验证了超声检测与有限元模拟相结合在分析和优化焊接参数以及预测残余应力分布方面的有效性。

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引用次数: 0

Strain hardening effect on TES collapse moment of different angled pipe bends subjected to bending moments 弯矩作用下不同角度弯头TES崩塌弯矩的应变硬化效应

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-10-01 DOI: 10.1016/j.ijpvp.2025.105673

Manish Kumar

Piping systems carry fluid from one location to another and pipe bends are one of the most critical component due to its large deformation and high stress bearing nature. Collapse moment is one the criteria that helps to determine the strength of the pipe bend. The present study carries extensive three dimensional analyses to calculate the collapse moment of pipe bends (30° to 180° with interval of 30°) using twice-elastic-slope (TES) method. This paper focuses on the strain hardening (SH) effect on TES collapse moment based on elastic perfectly-plastic (EPP) material model for different bend angle and piping thickness under in-plane (closing (IPC) and opening (IPO)) and out-of-plane (OP) bending modes. From the results, it is clear that pipe thickness has significant role on hardening effect. Under IPC and OP bending modes, thicker pipe bend shows maximum hardening effect whereas under IPO mode least pipe thickness shows maximum hardening behavior due to its deformation pattern. Strain hardening effect changes maximum when bend angle changes from 30° to 60° for all bending modes. The hardening effect does not changes much for bend angle 60° to 180° under IPC and OP bending modes. Under IPO bending, hardening effect depends on bend angle for thinner pipe bends and for thicker pipe bends, it is independent of bend angle. This study helps to evaluate the bend angle hardening behavior influence on TES collapse moment which ultimately help determine the SH material model TES collapse moment based on the EPP material model.

管道系统将流体从一个位置输送到另一个位置，由于其大变形和高应力承受特性，弯头是最关键的部件之一。坍塌力矩是确定弯管强度的标准之一。本研究采用双弹性斜率法（TES）对30°~ 180°、间隔为30°的弯道进行了广泛的三维分析计算。基于弹性完全塑性（EPP）材料模型，研究了面内（IPC）和面外（OP）弯曲模式下，不同弯曲角度和管道厚度下的应变硬化（SH）效应对TES坍塌力矩的影响。结果表明，管材厚度对硬化效果有显著影响。在IPC和OP弯曲模式下，较厚的弯管硬化效果最大，而在IPO模式下，最小的管厚由于其变形模式而表现出最大的硬化行为。在所有弯曲模式下，当弯曲角度从30°变化到60°时，应变硬化效果变化最大。在IPC和OP弯曲模式下，弯曲角度为60°~ 180°时，硬化效果变化不大。在IPO弯曲条件下，较细弯头的硬化效果与弯头角度有关，较粗弯头的硬化效果与弯头角度无关。本研究有助于评估弯角硬化行为对TES崩塌力矩的影响，最终确定基于EPP材料模型的SH材料模型TES崩塌力矩。

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引用次数: 0

Assessment of AM70 high-strength steel processed via wire arc additive manufacturing for pressure vessel applications: Role of spray and pulsed arc 压力容器用电弧丝增材制造加工的AM70高强度钢的评估：喷射电弧和脉冲电弧的作用

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-09-30 DOI: 10.1016/j.ijpvp.2025.105671

Nikita Kumari, Kumar Kanishka, Bappa Acherjee

Achieving optimal mechanical performance in wire arc additive manufacturing (WAAM) of high-strength low-alloy (HSLA) steels is critical for the structural integrity of load-bearing and pressure-retaining components. This study compares the effects of high-capacity Spray Arc and voltage-controlled Pulsed Arc gas metal arc welding (GMAW) modes on the microstructure, residual stress distribution, and mechanical behavior of AM70 HSLA steel, an alloy formulated for enhanced arc stability and deoxidation. Comprehensive characterization using optical/electron microscopy, X-ray diffraction, mechanical testing, and fractography reveals distinct process–structure–property relationships. Pulsed Arc mode produces a refined acicular ferrite matrix with more uniform crystallite size and elemental homogeneity, leading to superior hardness (236–246 HV₅ vs. 223–235 HV₅), tensile strength (743–793 MPa vs. 687–710 MPa), and Charpy impact toughness (78.5–103 J vs. 59.3–78.2 J) compared to Spray Arc. Additionally, compressive residual stresses are more uniformly distributed under Pulsed Arc (−134 to −288 MPa), whereas Spray Arc introduces steeper gradients (−66 to −311 MPa), which could affect long-term structural performance. Although Spray Arc yields higher ductility (34.7–36.4 % vs. 29.1–32.9 %), Pulsed Arc offers a better balance of strength and toughness. Fractographic analysis confirms ductile failure modes in both cases, with finer dimple morphology observed in Pulsed Arc samples. These findings demonstrate the potential of Pulsed Arc WAAM with AM70 steel for manufacturing pressure-resilient and structurally reliable HSLA steel components.

在高强度低合金（HSLA）钢的电弧增材制造（WAAM）中实现最佳机械性能对承载和保压部件的结构完整性至关重要。本研究比较了大容量喷射电弧和电压控制脉冲电弧气体金属电弧焊（GMAW）模式对AM70 HSLA钢的显微组织、残余应力分布和力学行为的影响，AM70 HSLA钢是一种旨在增强电弧稳定性和脱氧的合金。利用光学/电子显微镜、x射线衍射、力学测试和断口学进行综合表征，揭示了不同的工艺-结构-性能关系。脉冲电弧模式产生了精细的针状铁素体基体，具有更均匀的晶粒尺寸和元素均匀性，与喷射电弧相比，具有更高的硬度（236-246 HV5 vs 223-235 HV5），抗拉强度（743-793 MPa vs 687-710 MPa）和Charpy冲击韧性（78.5-103 J vs 59.3-78.2 J）。此外，脉冲电弧（- 134至- 288 MPa）下的残余压应力分布更均匀，而喷雾电弧的残余压应力梯度更陡（- 66至- 311 MPa），可能会影响结构的长期性能。尽管喷射电弧具有更高的延展性（34.7 - 36.4% vs 29.1 - 32.9%），但脉冲电弧具有更好的强度和韧性平衡。断口分析证实了两种情况下的延性破坏模式，在脉冲电弧样品中观察到更细的韧窝形态。这些发现证明了脉冲电弧WAAM与AM70钢在制造抗压力和结构可靠的HSLA钢部件方面的潜力。

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引用次数: 0

The role of heterogeneity and pop-in events when assessing brittle fracture in the weld metal of multi-pass welds 非均质性和弹出事件在评估多道次焊缝焊缝金属脆性断裂中的作用

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-09-26 DOI: 10.1016/j.ijpvp.2025.105664

Daniela V. Klein , Pål Efsing , Jonas Faleskog

Fracture toughness testing was conducted on 81 SE(B)-specimens extracted from the weld metal of an aged pressurizer weld, of which 42 were deep-cracked and 39 shallow-cracked specimens. The crack tips were positioned in distinct zones in the weld metal, which was achieved by polishing and etching the material to reveal prior-austenite grain boundaries prior to specimen manufacturing. Deep-cracked specimens with crack tips located in the as-welded zone and where dendrites exhibit a low inclination to the pre-crack plane, frequently showed pop-in events during testing. The length of these pop-ins correlated directly with the length of the weld zone in front of the crack tip. Toughness was evaluated both at the pop-in and at final failure, and values were assigned to the corresponding weld zones. The ductile-to-brittle transition temperature was determined separately for each zone, confirming that the as-welded zone with low dendrite inclination is the most critical in the aged weld.

对某增压器老化焊缝金属提取的81个SE(B)试样进行了断裂韧性试验，其中42个为深裂纹，39个为浅裂纹。裂纹尖端位于焊缝金属的不同区域，这是通过抛光和蚀刻材料来显示样品制造之前的奥氏体晶界来实现的。裂纹尖端位于焊接区且枝晶向预裂纹面倾斜较低的深裂纹试样，在试验过程中经常出现弹出事件。这些裂纹的长度与裂纹尖端前焊缝区的长度直接相关。在弹出和最终失效时对韧性进行了评估，并将数值分配给相应的焊接区域。分别测定了各区域的韧脆转变温度，确定了低枝晶倾角的焊接区是时效焊缝中最关键的区域。

引用次数: 0

Hydrodynamic pressures and mechanical behaviour of unanchored rigid tanks subjected to rocking accelerations 受摇摆加速度影响的非锚定刚性储罐的动水压力和力学行为

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-09-26 DOI: 10.1016/j.ijpvp.2025.105667

Enrico Zacchei , Reyolando Brasil , Tomoyo Taniguchi

Circular tanks are structures plated in industrial and nuclear plants usually used to storage water, petroleum, and gas. In seismic area they must be well design to avoid environmental and economic disasters due to possible content leaks. In codes the basic model to analyse the fluid-tank system consists in two components (impulsive and convective) under horizontal accelerations, thus rocking motions and uplifts are almost neglected. In this paper rigid unanchored tanks have been studied by considering the additional pressures generate by rocking motions and uplifts. For this, accurate analytical and parametrical analyses have been carried out in a dynamic and static way. The approximated solutions provided higher values in favour of safety in order to compensate the neglected rocking motions. The obtained pressures are useful to well estimate the hoop stresses in the base plate due to uplifts. For relative high rotations, a coupling interaction between sloshing and rocking is possible producing resonance effects that increase the maximum height of the sloshing wave favouring the leakage of the liquid. Results show that the rocking acceleration of a rigid tank under earthquakes cannot be neglected in any cases.

圆形储罐是工业和核电站中电镀的结构，通常用于储存水、石油和天然气。在地震区，它们必须设计得很好，以避免由于可能的内容泄漏而造成的环境和经济灾难。在代码中，分析液舱系统的基本模型在水平加速度下由两个部分组成（脉冲和对流），因此几乎忽略了摇摆运动和上升。本文对刚性无锚储罐进行了研究，考虑了摇摆运动和上升所产生的附加压力。为此，从动态和静态两方面进行了精确的分析和参数化分析。近似解提供了更高的安全值，以补偿被忽略的摇摆运动。所得到的压力有助于很好地估计由于上升而引起的底板环向应力。对于相对较高的旋转，晃动和摇摆之间的耦合相互作用可能产生共振效应，从而增加晃动波的最大高度，有利于液体的泄漏。结果表明，刚性储罐在地震作用下的振动加速度在任何情况下都不可忽视。

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引用次数: 0

The calibration of Hill48 anisotropic yield criterion for circular thin-walled tube bending 圆薄壁管弯曲Hill48各向异性屈服准则的标定

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-09-26 DOI: 10.1016/j.ijpvp.2025.105668

Xu Han , Zhi-Ping Guan , Jing-Ru Liu , Bao-Yan Zhao , Lei Gong , Yong Bi

Hill48 yield criterion has advantages in characterizing the anisotropy behavior of tube materials. In the study, a stress-based Hill48 yield criterion is presented specifically for circular tube bending, based on yield stresses rather than R-values. Its calibration is developed involving two uniaxial tensile tests along axial/circumferential direction, and one plane strain tensile test along axial direction of circular tube specimen, which match with the uniaxial tension states in 0° and 90° angles to the axial direction and the biaxial tension state, respectively, for identification of F, G and H values, and one torsion test for identification of N value. The FE models of rotary draw bending of SS 304 circular tube are established considering the stress-based Hill48 yield criterion. The simulation of tube bending indicates the stress-based Hill48 yield criterion can significantly improve the prediction accuracy of cross-section deformation in comparison with the strain-based Hill48 yield criterion and the Mises yield criterion. Compared with the traditional strain-based Hill48 yield criterion, the stress-based Hill48 yield criterion is more suitable for characterizing the bending behavior of circular tubes, which is primarily induced by flow stresses instead of plastic flow. Due to the compatibility of stress components, the stress-based Hill48 yield criterion is more suitable for modeling the anisotropic properties in circular tube bending while the testing method involving tube bulging is related to the plastic behavior in tube hydroforming.

Hill48屈服准则在表征管状材料的各向异性行为方面具有优势。在研究中，专门针对圆管弯曲提出了基于应力的Hill48屈服准则，该准则基于屈服应力而不是r值。其标定涉及两次沿轴向/周向的单轴拉伸试验和一次沿轴向的平面应变拉伸试验，分别与轴向0°和90°角的单轴拉伸状态和双轴拉伸状态相匹配，用于识别F、G和H值，以及一次用于识别N值的扭转试验。采用基于应力的Hill48屈服准则，建立了ss304圆管旋转拉伸弯曲的有限元模型。管材弯曲模拟结果表明，与基于应变的Hill48屈服准则和Mises屈服准则相比，基于应力的Hill48屈服准则能显著提高管材截面变形的预测精度。与传统的基于应变的Hill48屈服准则相比，基于应力的Hill48屈服准则更适合于描述圆形管的弯曲行为，圆形管的弯曲行为主要是由流动应力而不是塑性流动引起的。由于应力分量的相容性，基于应力的Hill48屈服准则更适合于模拟圆管弯曲的各向异性，而涉及管胀形的试验方法则与管液压成形的塑性行为有关。

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引用次数: 0

HTHA-induced degradation in boilers: A life assessment approach using advanced NDT, metallography, and strategic maintenance 锅炉中htha引起的退化：使用先进无损检测、金相学和战略维护的寿命评估方法

IF 3.5 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping

Pub Date : 2025-09-23 DOI: 10.1016/j.ijpvp.2025.105666

Nugroho Karya Yudha , Nosal Nugroho Pratama , Dwipa Fattamonas , Wahyuda Prakasa , Eka Wijayanto , Saiful Bahri , Akmal Irfan Majid , Deendarlianto , Muhammad Akhsin Muflikhun

This study presents a comprehensive life assessment of a Process Water Boiler affected by High-Temperature Hydrogen Attack (HTHA) after over 27 years of continuous operation. Constructed primarily from C-0.5Mo steel and subjected to elevated hydrogen partial pressures and temperatures up to 346.5 °C, the boiler was evaluated using a combination of advanced Non-Destructive Testing (NDT) techniques—Phased Array Ultrasonic Testing with Total Focusing Method (PAUT-TFM) and Magnetic Particle Inspection (MPI)—alongside hardness measurements and metallographic analysis. The PAUT-TFM revealed progressive HTHA damage in critical regions, with estimated damage progression rates ranging from 0.1 to 7.6 mm/year over a 10-month monitoring period. MPI confirmed the presence of a surface-breaking crack in the longitudinal weld near the inlet, accompanied by subsurface blistering and microcracking. Hardness testing identified significant softening, particularly at the inlet, with values falling below the typical hardness threshold for C-0.5Mo steel (157 HV), indicative of decarburization. Metallographic analysis corroborated these findings, revealing increased ferrite content and carbide depletion in HTHA-prone zones. The integration of destructive and non-destructive assessments confirms that the material has entered an advanced and irreversible degradation phase. Given the high structural risk and limited feasibility of repairs, the study recommends targeted component replacement using hydrogen-resistant alloys such as 1.25Cr-0.5Mo, guided by thermal exposure assessments and Nelson Curves. These findings emphasize the critical importance of early detection, informed material selection, strategic maintenance, and replacement planning to ensure long-term operational safety and reliability in hydrogen-intensive environments.

本文对一台连续运行27年以上的过程水锅炉进行了高温氢侵蚀的综合寿命评估。锅炉主要由C-0.5 mo钢建造，并承受高氢分压和高达346.5°C的温度，使用先进的无损检测（NDT）技术-相控阵超声检测与全聚焦法（pat - tfm）和磁粉检测(MPI) -以及硬度测量和金相分析相结合进行评估。在10个月的监测期间，pat - tfm显示关键区域的HTHA损伤进展，估计损伤进展率为0.1至7.6 mm/年。MPI证实在入口附近的纵向焊缝存在表面断裂裂纹，并伴有地下起泡和微裂纹。硬度测试发现明显的软化，特别是在进口处，其值低于C-0.5Mo钢的典型硬度阈值（157 HV），表明脱碳。金相分析证实了这些发现，揭示了htha易发区铁素体含量增加和碳化物耗尽。破坏性和非破坏性综合评估证实，该材料已进入高级和不可逆转的降解阶段。考虑到高结构风险和有限的维修可行性，该研究建议在热暴露评估和Nelson曲线的指导下，使用1.25Cr-0.5Mo等抗氢合金进行有针对性的部件更换。这些发现强调了早期检测、明智的材料选择、战略维护和更换计划的重要性，以确保在氢密集型环境中长期运行的安全性和可靠性。

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引用次数: 0