CN112504863A - Method for quantitatively evaluating service life of material - Google Patents
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- CN112504863A CN112504863A CN202011337008.9A CN202011337008A CN112504863A CN 112504863 A CN112504863 A CN 112504863A CN 202011337008 A CN202011337008 A CN 202011337008A CN 112504863 A CN112504863 A CN 112504863A
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- 238000000034 method Methods 0.000 title claims abstract description 64
- 239000000463 material Substances 0.000 title claims abstract description 32
- 230000032683 aging Effects 0.000 claims abstract description 78
- 238000012360 testing method Methods 0.000 claims abstract description 39
- 238000011156 evaluation Methods 0.000 claims abstract description 13
- 239000000203 mixture Substances 0.000 claims abstract description 4
- 230000035882 stress Effects 0.000 claims description 31
- 238000012423 maintenance Methods 0.000 abstract description 8
- 239000007769 metal material Substances 0.000 abstract description 7
- 239000002184 metal Substances 0.000 abstract description 5
- 238000011158 quantitative evaluation Methods 0.000 abstract description 3
- 229910000831 Steel Inorganic materials 0.000 description 8
- 239000010959 steel Substances 0.000 description 8
- 229910000734 martensite Inorganic materials 0.000 description 4
- 238000004364 calculation method Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000004643 material aging Methods 0.000 description 3
- 229910001562 pearlite Inorganic materials 0.000 description 3
- 229910000963 austenitic stainless steel Inorganic materials 0.000 description 2
- 238000013213 extrapolation Methods 0.000 description 2
- 230000002431 foraging effect Effects 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/08—Investigating strength properties of solid materials by application of mechanical stress by applying steady tensile or compressive forces
- G01N3/18—Performing tests at high or low temperatures
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/0058—Kind of property studied
- G01N2203/006—Crack, flaws, fracture or rupture
- G01N2203/0067—Fracture or rupture
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/022—Environment of the test
- G01N2203/0222—Temperature
- G01N2203/0226—High temperature; Heating means
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/06—Indicating or recording means; Sensing means
- G01N2203/067—Parameter measured for estimating the property
- G01N2203/0676—Force, weight, load, energy, speed or acceleration
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/06—Indicating or recording means; Sensing means
- G01N2203/067—Parameter measured for estimating the property
- G01N2203/0688—Time or frequency
Abstract
The invention provides a method for quantitatively evaluating the service life of a material, which comprises the following steps: determining the service life of the non-worn sample and the service life loss of samples with different aging grades; carrying out mathematical fitting on the aging grade and the service life loss to obtain a functional relation; carrying out aging rating on a sample to be tested; substituting the obtained aging rating result into the functional relation to obtain a life loss result; the sample and the sample to be tested have the same composition. On the basis of establishing the functional relationship between the aging grade and the service life loss, the invention carries out aging rating on the metallographic structure of the material on site, thereby quantitatively evaluating the residual service life of the metal material in service under specific conditions, guiding technical personnel to master the service life condition of the high-temperature metal component and formulating operation and maintenance strategies according to the service life condition. Compared with the traditional method, the method can conveniently and rapidly carry out quantitative evaluation on the service life of the material, thereby solving the problem of long time consumption of a service life evaluation test.
Description
Technical Field
The invention belongs to the technical field of life evaluation, and particularly relates to a method for quantitatively evaluating the life of a material.
Background
The creep damage of the metal material can occur when the metal material is in service at the temperature higher than 450 ℃, the high-temperature service life of the metal material mainly refers to the creep service life, and the creep service life refers to the time of creep rupture of the material at a specific temperature and constant stress. At present, a high-temperature endurance test is generally carried out by adopting a cut tube in a creep life calculation method, and because the design life of a furnace tube is generally 30 years and the creep test of 30 years is unrealistic, an accelerated test is actually carried out by a method of improving temperature or stress, and then the life is predicted by extrapolation. The commonly used calculation methods mainly include an isotherm extrapolation method, a time-temperature parameter method, a theta function method and the like.
At present, the traditional service life assessment method needs to cut pipes after a power plant is shut down, and the service life of materials is assessed by performing a durability test on the cut pipes, even if an acceleration method is adopted for performing the durability test, in order to guarantee the precision requirement, the test time cannot be less than 3000 hours, and the consumed time is long. The maintenance period of the power plant is generally short (about 1 month), the test is not finished when the maintenance period is finished, the test result cannot be obtained before the maintenance period is finished, the service life state of the metal part cannot be mastered, and corresponding measures cannot be taken, so that the potential safety hazard after the unit is operated is increased. Therefore, a simple and rapid method is needed, the service life of the material can be quantitatively evaluated in a short time, technical guidance is provided for a power plant, and the requirement of the power plant on maintenance period is met.
Disclosure of Invention
In view of the above, the present invention provides a method for quantitatively evaluating the lifetime of a material, which is simple, low in cost and short in time consumption.
The invention provides a method for quantitatively evaluating the service life of a material, which comprises the following steps:
determining the service life of the non-loss sample and the service life loss of samples with different aging grades;
carrying out mathematical fitting on the aging grade and the service life loss to obtain a functional relation;
carrying out aging rating on a sample to be tested;
substituting the obtained aging rating result into the functional relation to obtain the service life loss of the sample to be tested;
the sample has the same composition as the sample to be tested.
Preferably, the method for determining the lifetime of an unworn sample and the lifetime loss of samples of different aging grades comprises:
and selecting the samples without loss and the samples with different aging grades to respectively carry out high-temperature endurance strength tests, and obtaining the service life of the samples without loss and the service life loss of the samples with different aging grades according to the results of the high-temperature endurance strength tests.
Preferably, the aging grades of the samples with different aging grades are evaluated according to DL/T884-2019 'thermal power plant metallographic examination and evaluation technical guide rules', and are graded according to metallographic structures and carbide characteristics, wherein the aging grades are graded from light to heavy according to the aging degree to 1-5.
Preferably, the method for the high temperature endurance strength test comprises the following steps:
and (3) carrying out high-temperature endurance strength tests of different stresses on the sample at the same temperature to obtain the fracture time of the sample under different stresses.
Preferably, the temperature is the service temperature of the sample to be detected.
Preferably, the stress is 100 to 200 MPa.
Preferably, the method for calculating the lifetime loss includes:
residual life of lossless sample is tau0The residual life of the samples of different aging grades is tauiAnd Φ is lifetime loss:
preferably, the method for obtaining the residual life of the sample comprises the following steps:
according to the fracture time of the sample under different stresses obtained by the high-temperature endurance strength test, establishing a functional relation between the stress and the fracture time; and substituting the service stress of the sample to be tested into the functional relation to obtain the sample fracture time, namely the residual life.
Preferably, the method for mathematically fitting the aging level and the lifetime loss includes linear fitting, nonlinear least squares fitting, and the like.
Preferably, the method for aging rating of the sample to be tested comprises:
and (3) evaluating according to DL/T884 plus 2019 < thermal power plant metallographic examination and evaluation technical guide rules >, grading according to metallographic structures and carbide characteristics, and grading from light to heavy according to aging degree to 1-5.
The method quantitatively evaluates the service life of the material through the metallographic structure aging rating, and quantitatively evaluates the residual service life of the metal material in service under specific conditions through carrying out the aging rating on the metallographic structure of the material on the basis of establishing a functional relation between the aging rating and the service life loss, guides technical staff to master the service life condition of the high-temperature metal component, and accordingly makes operation and maintenance strategies. Compared with the traditional method, the method can conveniently and rapidly carry out quantitative evaluation on the service life of the material, thereby solving the problem of long time consumption of a service life evaluation test.
Aiming at the problem that the service life assessment test in the prior art consumes a long time, the method can conveniently and quickly carry out quantitative assessment on the service life of the material by using a simple metallographic structure aging rating method on the basis of obtaining the functional relation between the material aging grade and the service life loss, thereby solving the problem that the service life assessment test consumes a long time.
Drawings
FIG. 1 is a process flow diagram of a method for quantitatively evaluating life of a material according to an embodiment of the present invention;
FIG. 2 is a graph of aging level as a function of age loss as provided in example 1 of the present invention;
FIG. 3 is a graph of aging level as a function of age loss as provided in example 2 of the present invention;
FIG. 4 is a creep curve equation obtained after fitting provided in example 2 of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other examples, which may be modified or appreciated by those of ordinary skill in the art based on the examples given herein, are intended to be within the scope of the present invention. It should be understood that the embodiments of the present invention are only for illustrating the technical effects of the present invention, and are not intended to limit the scope of the present invention. In the examples, the methods used were all conventional methods unless otherwise specified.
The method for quantitatively evaluating the service life of the material through the metallographic aging rating is used for quantitatively evaluating the residual service life of a service metal material at high temperature, guiding technical personnel to master the health condition of a high-temperature metal component and accordingly making an operation and maintenance strategy, and the flow of the method for quantitatively evaluating the service life of the material provided by the embodiment of the invention is shown in figure 1.
The invention provides a method for quantitatively evaluating the service life of a material, which comprises the following steps:
determining the service life of the samples without loss and the service life loss of the samples with different aging grades;
carrying out mathematical fitting on the aging grade and the service life loss to obtain a functional relation;
carrying out aging rating on a sample to be tested;
substituting the obtained aging rating result into the functional relation to obtain a life loss result;
the sample and the sample to be tested have the same composition.
In the invention, the non-loss sample is a non-service sample and has no service life loss.
In the invention, the samples with different aging grades are evaluated according to DL/T884-2019 'thermal power plant metallographic examination and evaluation technical guide rules', are graded according to metallographic structures and carbide characteristics, and are graded into 1-5 grades according to the aging degree from light to heavy.
In the present invention, the lifetime of the non-worn sample and the lifetime loss of the samples of different aging grades can be obtained by published literature data or by experimental methods. In the present invention, the lifetime of the non-worn sample and the lifetime loss of the samples of different aging grades are preferably determined by a high temperature endurance test, and the specific method preferably comprises:
and respectively carrying out high-temperature endurance strength tests on the samples without loss and the samples with different aging grades, and obtaining the service life loss according to the results of the high-temperature endurance strength tests. In the present invention, the method of the high temperature endurance test preferably includes:
and (3) carrying out high-temperature endurance strength tests on the sample at the same temperature under different stresses to obtain the fracture time of the sample under different stresses.
In the invention, the temperature is preferably the service temperature of a sample to be tested, the stress is preferably 100-200 MPa, the fracture time of the test sample under the stress of 100-200 MPa is preferably tested in the high-temperature endurance strength test process, more preferably, the fracture time of 5-7 groups of samples under the stress of 100-200 MPa is tested, more preferably, 6 groups of samples are tested, namely, 6 different stress values are selected between 100-200 MPa to respectively test the fracture time of the samples, and the fracture time of the test sample under the stresses of 100MPa, 110MPa, 120MPa, 150MPa, 160MPa and 190MPa is most preferably selected.
In the invention, the service life loss reflects the loss degree of the total service life caused by material aging, and the residual service life is tau obtained by selecting a non-loss sample to carry out a high-temperature endurance strength test0，τ0Total lifetime, τ, of the unconsumed sampleiThe residual life of the samples with different aging levels is shown, and phi is the life loss, and the residual life is calculated by the following formula:
in the present invention, it is preferred to establish a functional relationship between the stress and the time to failure of the sample according to the time to failure of the sample under different stresses; and substituting the service stress of the sample to be tested into the functional relation to obtain the residual life of the sample.
The method for establishing the functional relationship between the stress and the fracture time of the sample is not particularly limited, and the method for establishing the functional relationship, which is well known to those skilled in the art, can be adopted, for example, the method can be used for establishing the functional relationship by using mathematical tool software such as origin, matlab and the like.
In the invention, the mathematical fitting is to construct a function on a group of data by a mathematical means so that the data is infinitely approximated by the function, so that the function can describe the rule of the group of data. The invention fits the life loss values phi and the aging grades i of samples with different aging grades to obtain a functional relation:
f＝f(i,φ)。
in the present invention, the functional relationship is related to the operating conditions (temperature and pressure) and to the material itself, and different materials such as pearlite heat-resistant steel, martensite heat-resistant steel, and austenitic stainless steel have different characteristics, and the functional relationship between the aging grade and the life loss is different, and the functional fitting should be performed for each material.
The mathematical fitting method of the present invention is not particularly limited, and may be a mathematical fitting method known to those skilled in the art, and the mathematical fitting method for the aging level and the lifetime loss includes linear fitting, nonlinear least squares fitting, and the like, for example, the fitting may be performed by using mathematical tool software such as origin, matlab, and the like.
In the present invention, the method for aging rating a sample to be tested preferably includes:
and (3) evaluating according to DL/T884 plus 2019 < thermal power plant metallographic examination and evaluation technical guide rules >, grading according to metallographic structure and carbide characteristics, grading from light to heavy according to aging degree to 1-5 grade, and reflecting the degree of material structure degradation.
In the invention, according to the specification of DLT 884-; different grading standards are adopted to respectively grade different materials such as pearlite heat-resistant steel, ferrite heat-resistant steel, austenitic stainless steel and the like, and the ageing grade is 1-5 grades from light to heavy according to the ageing severity.
According to the aging grade and the life loss functional relation, the life loss of the sample to be tested can be obtained by bringing the aging grade into the functional relation, and the residual life of the material is further evaluated.
The method solves the problems that the service life of the material needs to be evaluated on site, the destructive test needs to be carried out by cutting the pipe, and the test consumes longer time. According to the method, the service life loss of the material can be conveniently and quickly obtained through the on-site metallographic structure aging rating on the basis of establishing the functional relation between the material aging grade and the service life loss, so that the residual service life of the material is evaluated, and the method is simple, low in cost and short in time consumption.
Example 1
Mathematical fitting was performed on the aging grade and life loss of pearlite heat-resistant steel 12Cr1MoV, table 1 is the residual life of samples of different aging grades:
TABLE 112 endurance life of different aging levels of Cr1MoV
The aging level and the life loss are fitted to obtain a functional relationship f (i, Φ) of the two, as shown in fig. 2.
Example 2
The service life evaluation method for the pipeline with the heating surface of the martensite heat-resistant steel T91 in service in the power plant comprises the following steps:
selecting an undamaged T91 sample and a T91 sample with an aging grade of 1-5 grades respectively (aging grade evaluation is carried out according to DLT 884-.
Knowing the pipeline specification and the operating pressure, the calculation of the internal pressure stress of the pipeline is carried out by the following formula:
where σ is the internal pressure stress in the pipe, p is the operating pressure, D0Is the pipe outside diameter and s is the pipe wall thickness.
Substituting the pipeline internal pressure stress sigma into the creep equation to obtain the residual life of the non-loss sample and the samples with different aging grades, wherein the residual life of the non-loss sample is the total life, and the ratio of the difference between the total life and the residual life of the samples with different aging grades to the total life is the life loss. Table 2 residual life for different aging grade samples:
TABLE 2 residual Life of different aging grade samples of T91
The aging grade and the life loss of the martensite heat-resistant steel T91 are mathematically fitted to obtain a functional relationship f (i, phi) between the two, as shown in FIG. 3.
Aging rating is carried out on the pipeline of the heating surface of the martensite heat-resistant steel T91 to be tested according to the regulations of DLT 884-2019 'thermal power plant metallographic examination and evaluation technical guide' and the rating result is that the aging grade is 2.5 grade;
according to the functional relationship (fig. 3), substituting the aging level of 2.5 results in that the life loss Φ of the T91 pipeline is 51%, the total life is 192000h, and the remaining life is 94000 h.
In order to verify the result, a high-temperature endurance strength test is carried out on the T91 pipeline cut pipe, the test temperature is 570 ℃, the test of the breaking time is carried out under the conditions that the pressure is 100MPa, 110MPa, 120MPa, 150MPa, 160MPa and 180MPa respectively, and the longest breaking time is 7356 h; the stress and the fracture time are mathematically fitted to obtain a creep curve equation as shown in fig. 4, the specification of the pipeline on the T91 heating surface in service is phi 48 multiplied by 6.6mm, the operating pressure is 25.4MPa, the internal pressure stress sigma of the pipeline is calculated to be 79.7MPa, the stress sigma is substituted into the creep curve equation to obtain the service life tau of 96161h, and compared with the residual service life 94000h tested by the invention, the error is 2.2%.
The method quantitatively evaluates the service life of the material through the metallographic structure aging rating, and quantitatively evaluates the residual service life of the metal material in service under specific conditions through carrying out the aging rating on the metallographic structure of the material on the basis of establishing a functional relation between the aging rating and the service life loss, guides technical staff to master the service life condition of the high-temperature metal component, and accordingly makes operation and maintenance strategies. Compared with the traditional method, the method can conveniently and rapidly carry out quantitative evaluation on the service life of the material, thereby solving the problem of long time consumption of a service life evaluation test.
While only the preferred embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
Claims (10)
1. A method of quantitatively evaluating material life, comprising:
determining the service life of the non-loss sample and the service life loss of samples with different aging grades;
carrying out mathematical fitting on the aging grade and the service life loss to obtain a functional relation;
carrying out aging rating on a sample to be tested;
substituting the obtained aging rating result into the functional relation to obtain the service life loss of the sample to be tested;
the sample has the same composition as the sample to be tested.
2. The method of claim 1, wherein the method of determining the life of the non-worn sample and the life loss of the samples of different aging grades comprises:
and selecting the samples without loss and the samples with different aging grades to respectively carry out high-temperature endurance strength tests, and obtaining the service life of the samples without loss and the service life loss of the samples with different aging grades according to the results of the high-temperature endurance strength tests.
3. The method as claimed in claim 1, wherein the aging grades of the samples with different aging grades are evaluated according to DL/T884-2019 'thermal power plant metallographic examination and evaluation technical guide rules', and the samples are graded according to metallographic structures and carbide characteristics from light aging degree to heavy aging degree to 1-5.
4. The method of claim 2, wherein the method of high temperature proof strength testing comprises:
and (3) carrying out high-temperature endurance strength tests of different stresses on the sample at the same temperature to obtain the fracture time of the sample under different stresses.
5. The method of claim 4, wherein the temperature is a service temperature of the sample to be tested.
6. The method according to claim 4, wherein the stress is 100 to 200 MPa.
7. The method of claim 1, wherein the method of calculating the life loss comprises:
residual life of lossless sample is tau0The residual life of the samples of different aging grades is tauiAnd Φ is lifetime loss:
8. the method of claim 7, wherein the method of obtaining the remaining life of the sample comprises:
according to the fracture time of the sample under different stresses obtained by the high-temperature endurance strength test, establishing a functional relation between the stress and the fracture time; and substituting the service stress of the sample to be tested into the functional relation to obtain the sample fracture time, namely the residual life.
9. The method of claim 1, wherein the method of mathematically fitting the age level and the life loss comprises: linear fitting, nonlinear least square fitting.
10. The method of claim 1, wherein the method of aging a test sample comprises:
and (3) evaluating according to DL/T884 plus 2019 < thermal power plant metallographic examination and evaluation technical guide rules >, grading according to metallographic structures and carbide characteristics, and grading from light to heavy according to aging degree to 1-5.
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