ML19261B225
| ML19261B225 | |
| Person / Time | |
|---|---|
| Site: | Dresden  |
| Issue date: | 08/08/1977 |
| From: | Webb Patricia Walker GENERAL ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML19261B218 | List: |
| References | |
| 77-509-70, NUDOCS 7902140264 | |
| Download: ML19261B225 (19) | |
Text
@
PME TRANSMITTAL NO. 77-509-70 l
AUGUST 1977 DRESDEN 1 RADIATION LEVEL PROGRAM CORROSION TESTS PROGRESS REPORT NUCLEAR ENERGY BUSINESS GROUP e SAN JOSE, CALIFORNI A 95125 GENER AL h ELECTRIC aema m
GENERAL @ ELECTRIC PME TRANSMITTAL NO.
77-509-70 NUCLEAR ENERGY D1 VISION PLANT MATERIALS ENGINEERING INTERIM REPORT FRACTURE MECHANICS TESTS OF SIMULATED CLAD CRACKS IN ASTM A336 Gr. F1 EXPOSED TO DOW NS-1 CLEANING SOLVENT August 8, 1977 PREPARED BY: ME 4
W. L. Walke.-
Plant Material. & Process Development APPROVED SY:.
' [. / f/fr [ /
- y. C. Dadco, Manager Plant Materials & Process Development APPROVED BY:
G. M. Gordon, Manager Plant Materials Engineering DISTRIBUTION T. E. ADAMS (12)
G. M. GORDON L. D. ANSTINE J. H. HOLLOWAY R. L. COWAN C. P. RUIZ J. C. DANK 0 M. T. WANG W. L. CLARKE D.
WEINSTEIN
DISCLAIMER OF RESPONSIBILITY This document was prepared by the General Electric Company DJsuant to a contract with the Commonwealth Edison Company.
Except as otherwise provided in such contract, neither the General Electric Company nor any of the contributors to this document nor any of the sponsors of the work makes any warranty or representation (express or implied) with respect to the accuracy, completeness, or usefulness of the information contained in this document or that the use of such information may not infringe privately owned rights; nor do they assume any responsibility for liability or damage of any kind which m3y result from the use of any of the information contained in this document.
INTERIM REPORT FRACTURE MECHANICS TESTS OF SIMULATED CLAD CRACKS IN ASTM A336 Gr. F1 EXPOSED TO 00W NS-1 CLEANING SOLVENT by W.L. Walker INTRODUCTION During the proposed Dresden 1 chemical cleaning operation, the exposure of bare carbon steels and low alloy steels will be minimized.
However, a number of areas of stainless steel-clad carbon and low alloy steels will be exposed to the solvent (NS-1). Questions
..o raised during discussions with Commonwealth Edison personnel regarding the effects of exposure to NS-1 on the propagation of any through-clad cracks which might exist at these locations. An expanded fracture mechanics corrosion test program was initiated to provide answers to this question, and questions related to subsequent service behavior of existing cracks following exposure to NS-1.
The steels of interest were A336 F-1, A302 B, A335 P-1, A106 B, and A105.
This report summarizes the data generated for A336 F-1, and work is in progress to evaluate the other four alloys.
SUMMARY
Simulated clad-cracked 1-T WOL fracture mechanics specimens were prepared from three different heats of A336 F-1 material which had been weld clad in the notch area and post-weld heat treated. A fatigue pre-crack was initiated in the stainless steel weld deposit, and stainless steel cover plates were electrically coupled to five sides of the specimens, to give a very large cathode-to-anode surface area ratio at the tip of the crack in the low alloy steel base metal. Triplicate soecimens from each heat were loaded to stress intensities of 90,000 psi \\ fili and duplicate specimens were loaded to 45,000 psi \\ fili
, and exposed to a simulated cleaning cycle of 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> at 250 F (121 C).
In addition, triplicate specimens from each heat were loaded to 90,000 psi G and exposed to demineralized water at 250 F for 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> as controls. Following the 250 F exposures, all specimens were subjected to simulated BWR service exposures totalling 688 hours0.00796 days <br />0.191 hours <br />0.00114 weeks <br />2.61784e-4 months <br />, with examinations at 167, 405, and 688 hours0.00796 days <br />0.191 hours <br />0.00114 weeks <br />2.61784e-4 months <br />.
Examination of the specimens following the NS-1 exposure revealed galvanic corrosion at the clad-base metal interface, and crevice corrosion in the fatigue pre-crack on two of the three heats. The third heat exhibited minor galvanic corrosion at the interf6ce and slight crevice corrosion in the pre-crack.
No evidence of deleterious crack propagation was observed on any of the specimens exposed to NS-1.
Examinations made during the simulated BWR service exposures did not indicate any evidence of accelerated crack extension on any of the specimens, resulting from exposure to NS-1.
DETAILED DISCUSSION Materials Three different heats of ASTM A336 F-1 steel forgings were purchased in the form of 3-1/2 inch by 5 inch bars, and all materials were certified as 0
meeting ASTM requirements. Room temperature and 550 F mechanical properties tests were performed on specimens from each heat, and chemical analyses for the principal alloying elements and residual elemen;s were performed by an outside laboratory. Yield strengths measured in BWRSD tests tended to be somewhat lower than those reported in the material certifications, but all were well above the specified minimum value. Chemical analyses gave results which were identical to those reported on the certifications, within normal analytic error for particular elements. All elements were within specification limits. A detailed listing of mechanical properties and chemical compositions will be included in the final report on the fracture mechanics test program.
Specimen Fabrication A groove was machined in a section of bar from each material, filled with Type 309/308 weld metal to simulate cladding, and the weli.ad assembly U
0 was heat treated for three hours at 1150 F (620 C).
Slabs were cut from each section and machined into 1-T 'al (wedge-opening loaded) specimens, with the notch oriented in the S-T direction as per ASTM E399. Eight specimens were machined from each heat of material, and were then fatigue pre-cracked in accordance with ASTM E399 through the stainless steel weld deposit, into the low alloy steel base metal.
Holes were drilled and tapped in each specimen for subsequent attachment of stainless steel cover plates to simulate the effectively infinite ratio of surface area associated with a cladding crack.
- Specimen Loading The stress intensities selected for this series of tests were 90 ksi in and 45 ksi in. Compliance curves were generated on single specimens from each heat, and the crack opening displacement (C0D) values required for the selected stress intensities were calculated for each of the 24 specimens.
The specimens were loaded with a torque wrench, with continuous C0D value measurement, to the selected levels.
Six specimens from each heat were loaded to the 90 ksi level, and two specimens from each heat were loaded to the 45 ksi level. Crack lengths were re-measured after loading of each specimen.
Specimen Exposure and Crack Length Measurements Prior to exposure of the specimens, five of the six machined faces were masked with a pressure-sensitive silicone rubber gasketing material to exclude solvent from the stainless cover plate-low alloy steel crevice area. The specimen face lef t open was the notched face, to permit free access of test solutions to the crack tip.
The stainless steel cover plates were then bolted to the specimens, and the specimens were exposed to the test solutions; as shown in Figure 1.
Three of the high stress intensity specimens from each heat were exposed 0
to demineralized water at a temperature of 250 F hr a total of 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> at temperature. These specimens acted as controls for the determination of the effects of exposure to NS-1.
The remaining specimens from each heat were then exposed to simulated "used" NS-1 solution which had been nitrogen sparged for four hours prior to insertion of the specimens. The test vessel was a Teflon-lined pipe spool piece, with Teflon-lined blind flanges for closures.
The solution volume-to-surface area ratio during the NS-1 exposure 2
was approximately 1 gal /ft.
Specimens were exposed to the NS-1 solution for 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> at 250 F, with heat-up and cool-down periods of approximately 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> each.
Following the initial exposure to either demineralized water or NS-1, the cover plates were removed from the specimens and the siliccne rubber gaskets were stripped off. Crack length measurements were made optically, when possible, and photographically when optical measurements provec to be inadequate.
Some grinding of specimens exposed to NS-1 was required to remove corrosion product resulting from general pitting attack which occured on the exposed surfaces, and to clearly delineate the notch and crack tip where crevice and galvanic corrosion occured. Light polishing of the control specimens which were exposed to demineralized water was required in order to measure crack lengths on those specimens.
Following crack length measurements on the control and simulated NS-1 cleaning cycle specimens, the stainless steel cover plates were replaced on all specimens. The specimens were then subjected to three exposure periods in simulated BWR water (0.2 ppm oxygen, 550 F) with durations of 167, 238, and 283 hours0.00328 days <br />0.0786 hours <br />4.679233e-4 weeks <br />1.076815e-4 months <br />. The initial exposure was begun with the specimens imersed in air-saturated water which was displaced from the auroclave during heat-up by 0.2 ppm oxygen water. The two subsequent exposures were begun with normal loop water at a lower oxygen level. After each exposure period, the specimens were removed from test, the side cover plates were removed, and crack length measurements were made. Throughout the entire program, the specimens were stored under conditions of 100% relative humidity when not actually on test, in order to prevent dehydration of corrosion products in the crack tip; except during optical and photographic measurement of crack lengths.
RESULTS Specimen Examinations Optical measurements of crack lengths were made on all of the control specimens initially exposed to 250 F demineralized water at each examination period. Light hand polishing of the side groove with 120 - 600 grit silicon carbide paper was necessary in order to delineate the cracks clearly, and a typical example is shown in Figure 2.
The specimens exposed to NS-1 suffered varying degrees of corrosion, and optical measurements of crack lengths were not possible because of the Two of the three shallow depth of focus of the optical measuring equipment.
heats of material were heavily attacked and required air tool grinding of the side groove to reach base metal and achieve satisfactory delineation of the notch root and crack.
The third heat did not exhibit such heavy attack, and only light grinding and hand polishing were sufficient to delineate the By agreement with Dow Nuclear SeNices, only a single specimen from crack.
the high stress intensity group of each heat was ground heavily, in order to avoid compromising the fracture mechanics aspect of the specimens through reduction of the specimen thickness.
Photographic measurements of crack lengths were made on those specimens which were ground to delineate the cra::k.
In addition, photographic measurements were also made on one control specimen from each heat of material at each examination period to provide a check on the accuracy of the photographic method, as compared to the optical method.
Demineralized Water Control Exposure No evidence of crack propagation was observed on any of the specimens U
following exposure to demineralized water at 250 F for 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br />. A photograph of a tyypical crack is shown in Figure 2.
"Used" NS-1 Exposure Heavy attack was observed on two of the three heat of material following 0
100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> exposure to synthetic "used" NS-1 at 250 F, while the third heat exhibited relatively lighter attack.
Photographs of those specimens which were selected for grinding are shown in Figures 3 and 4, both before and after grinding. The specimen from the third heat is shown in Figure 5, in the same conditions.
While relatively severe galvanic corrosion occured at the stainless / low alloy steel interface, and crevice corrosion has occured within the fatigue pre-crack, only one heat gave indications of crack extension (.02 inches), and that value was approximately equal to the general crevice corrosion which occured in the fatigue pre-crack.
Simulated BWR Exposures As stated previously, all specimens were exposed to three periods in 0
simulated BWR water (0.2 ppm oxygen, 550 F), with the first startup made in air-saturated water.
Photographs of the specimens selected for grinding from those exposed to NS-1 are shown in Figures 6, 7, and 8.
Exposure to high temperature water results in dissolution of the corrosion product from the initial NS-1 exposure, but not in significant crack extension.
Crack Length Measurements Optical crack length measurements were made on all three control specimens from each heat of material, following each exposure period.
Photographic crack length measurements were made on one control specimen from each heat following each exposure, and on all control specimens following the final simulated BWR exposure.
Photographic measurements were also made on single high stress intensity specimens from each heat following each exposure, and on all specimens from the heat which exhibited the least attack in the NS-1 exposure after the final BWR exposure. The results of these measurements are shown in Table 1.
Fracture Surfaces Following the final simulated BWR exposure, one low stress intensity specimen from each heat was fractured at room temperature to assure that the crack length measurements which had been made were not seriously in error becuse of irregular crack front shape. All specimens exhibited straight crack frcnts, as shown in Figure 9.
Two high stress intensity specimens from each heat of material are still intact and in storage under 100% relative humidity conditions, and could be fractured if questions should arise.
CONCLUSIONS The results of this portion of the fracture mechanics corrosion test program indicate that exposure to NS-1 will not have a deleterious effect on propagation of existing through-clad cracks; either during the cleaning operation itself, or in subsequent service. Some undercutting of the clad may occur, which may extend as much as 0.1 inch on either side of the crack, as a result of galvanic and crevice corrosion.
Some crevice corrosion may occur in the base metal at existing cracks which may widen them somewhat, and possibly increase their depth. The maximum increase in depth indicated by the results of this investigation would appear to be less than.05 inches.
Only one heat of the three tested gave indications of crack propagation during the BWR exposures, and the difference between the control specimens and those which had been exposed to NS-1 was not significant.
TABLE 1 Crack Length - Inches (parenthesised Valtes are Photographic Measurements)
PRE-NS-1 or HEAT #
SPECIMEN N0.
EXPOSURE DI WATER BWR-1 BWR-2 BWR-3 210832 P-33(I}
.154
.150 (.177)
.200 (.
3)
.200 (.193)
.199 (.190) 210832 P-36(2)
.148
(.170)
(.195)
(.193)
(.186) 43563 Q-33(I)
.153
.149 (.140)
.150 (.151)
.152 (.147)
.153 (.155) 43563 Q-36(2)
.175
(.156)
(.187)
(.183)
(.186) 45716 R-31(I)
.160
.134 (.145)
.150 (.151)
.151 (.176)
.159 (.159) 45716 R-32(I)
.160
.167 (.158) 45716 R-33(I)
.155
.157 (.155) 45716 R-34(3)
.175
(.146)
(.126)
(.183)
(.180) 45716 R-35( )
.133
' 127)
(.149)
(.156)
(.153) 45716 R-36(2)
.170
(.166)
(.165)
(.169)
(.158)
I2}
45716 R-37
.149
(.156)
(.173)
(.165)
(.171) 45716 R-38(2)
.159
(.149)
(.130)
(.164)
(.175)
Notes:
(1) Control specimen; no NS-1 exposure (2) 90 ksi specimen exposed to NS-1 (3) 45 ksi specimen exposed to NS-1
Fabrication and exposure sequence FIGURE 1 for 1-T WOL specimens.
I L
Weld groove in A336 F1
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k Fatigue pre-crack through 308 SS to A336 base metal.
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with periodic examinations.
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Specimen Q-36 (Ht. No. 43563)
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Specimen R-36 (Ht. No. 45716)
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Hand-polished for each photograph' (8.6 X).
Specimen P-36 (Ht. No. 210832)
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Hand-polished for each photograph (8.6 X).
Specimen Q-36 (Ht. No. 43563)
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Hand-polished for each photograph (8.6 X).
Specimen R-36 (Ht. No. 45716)
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FIGURE 9 - Room temperature fracture faces of 45 ksi %
specimens after 688-hours simulated BWR exposure.
All photographs 3.9 X.