ML19261B228
| ML19261B228 | |
| Person / Time | |
|---|---|
| Site: | Dresden  |
| Issue date: | 01/05/1978 |
| From: | Webb Patricia Walker GENERAL ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML19261B218 | List: |
| References | |
| 78-509-002, 78-509-2, NUDOCS 7902140267 | |
| Download: ML19261B228 (22) | |
Text
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PME TRANSMITTAL NO. 78-509-002 DECEMBER 1977 DRESDEN 1 RADIATION LEVEL PROGRAM CORROSION TESTS PROGRESS REPORT 4
NU' LEAR ENERGY BUSINESS GROUP # SAN JOSE, CAllFORNIA 95125 GENER AL h ELECTRIC
-qo a\\A oK
GENERAL @ ELECTRIC PME TRANSMITTAL N0.
78-509-002 NUCLE AR ENERGY DIVISION PLANT fiATERIALS ENGINEERING INTERIM REPORT FRACTURE MECHANICS TESTS OF SIMULATED CLAD CRACKS IN ASTM A335-P1, A302-B, A106-B, and A105 EXPOSED TO DOW NS-1 CLEANING S0LVENT January 5,1978 M4 eM PREPARED BY:
W. L. WALKER Plant Materials & Process Development
[ [ / //ec h APPROVED BY:
J/ C. DANK 0, MANAGER Plant Materials & Process Development NI bA k APPROVED BY:
A
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G. M. GORDON, MAfMGER Plant Materials E ineering APPROVED BY:
R. A. PROEBSTLE, MANAGER Applied Metallurgy & Chemistry DISTRIBUTION T. E. Adams - 12 R. L. Cowan J. C. Danko G. M. Gordor.
R. A. Proebstle THE DATA PRESENTED IN THIS REPORT WERE GENERATED IN A CUSTOMER-FUNDED CONTRACT AND SHALL BE TREATED AS PROPRIETARY INFORW. TION.
DISCLAIMER OF RESPONSIBILITY This document was prepared by the General Electric Company pusuant to a contract with the Coninonwealth 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 may result from the use of any of the information contained in this document.
INTERIM REPORT FRACTURE MECHANICS TESTS OF SIMULATED CLAD CRACKS IN ASTM A335-P1, A302-B, A106-B, and A105 EXPOSED TO DOW 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 were 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-l.
The steels of interest were A336-F1, A302 B, A335-P1, A106-B, and A105.
This report summarizes the data generated for single heats of the last four alloys, and work is in progress to evaluate additional heats of these four alloys.
Data generated on multiple heats of A336-F1 has been previously reported in PME Transmittal No. 77-509-70, August, 1977.
SUMMARY
Simulated clad-cracked 1-T WOL fracture mechanics specimens were prepared from single heats of 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 specimens from each heat were loaded to stress intensities of 90,000 psi
\\ fin and duplicate specimens were loaded to 45,000 psi \\fUi, and exposed to a simulated cleaning cycle of U
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 \\Bri and exposed to demineralized water at U
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 647 hours0.00749 days <br />0.18 hours <br />0.00107 weeks <br />2.461835e-4 months <br />, with examinations at 144, 312 and 647 hours0.00749 days <br />0.18 hours <br />0.00107 weeks <br />2.461835e-4 months <br />.
Examinations of the specimens following the NS-1 exposure revealed varying degrees of galvanic corrosion at the clad-base metal interface, and crevice corrosion in the fatigue pre-crack, on all four alloys.
No evidence of deleterious crack propagation was observed on any of the specimens exposed to NS-1.
Crack length measurements made photographically during the simulated BWR exposure did not indicate any evidence of accelerated crack extension on any of the specimens resulting from exposure to NS-1.
However, destructive metallographic examinations performed on eingle specimens from each heat did indicate some crack extension occurred in the A105 specimen exposed to NS-1, without exidence of similar extension being observed on the control specimen from this alloy.
The apparent extension was approximately 0.020 inches.
Longer term exposure of specimens will be required to evaluate the significance of this observation.
DETAILED DISCUSSION Materials Single heats of the following materials, in the indicated product forms, were tested in this run; ASTM A335 Gr. P1 (Heat No. 3253,16" OD, 1.22" wall), A302 Gr. B (Heat No. 2529, 3" plate), A106 Gr. B (Heat No.
66549,12.75"0D,1.31" wall), and A105 (Heat No. 38875,13.25"00,1.25" wall).
Additional heats of each alloy are being tested in the next run. Mechanical properties tests and chemical analyses were performed on each material.
All elements were within specification limits, and a detailed listing of both mechanical properties and composition will be presented in the
.nal report on the fracture mechanics test program.
Specimen Fabrication Specimen fabrication was basically the same as in the previous run, with the plate material being grooved, welded, post-weld heat treated, and then final machined into ASTM A399 l-T WOL specimens.
In the three piping materials, rough specimen blanks were machined from the pipe walls, tack-welded together to form a bar, and then grooved, welded, post-weld heat treated, and final machined.
All post-weld heat treatments consisted of three hours at 1150 F with a furnace cool.
Eight specimens were machined from each material, cover plate attachment holes were tapped, and the specimens were fatigue pre-cracked in accordance with ASTM A399 into the base metal.
Specimen Loading The stress intensities selected for this series of tests were 90 ksi in and 45 ksi Min ~.
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 speci-mens.
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 spec.imens 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 left 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.
Three of the high stress intensity specimens from each heat were exposed to demineralized water at a temperature of 250 F for a total of approximately 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 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 2
ratio during the NS-1 exposure was approximately 1 gal /ft.
Specimens were exposed to the NS-1 solution for approximately 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> at 250 F.
Following the initial exposure to either demineralized water or NS-1 the cover plates were removed from the specimens and the silicone rubber gaskets were stripped off.
Crack length measurements were made optically, when possib
, and photographically when optical measurements proved to be inadequate.
Some grinding of specimens exposed to NS-1 was required to remove corrosion product resulting from general pitting attack which,ccurred on the exposed surfaces, and to clearly delineate the notch and crack tip where crevice and galvanic corrosion occurred.
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 specirens, 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 144,168, and 335 hours0.00388 days <br />0.0931 hours <br />5.539021e-4 weeks <br />1.274675e-4 months <br />.
The initial exposure was begun with the specimens immersed in air-saturated water which was displaced from the autoclave during heat-up by 0.2 ppm oxygen water.
The two subsequent exposures were begun with normal loop water at the 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 n]t actually on test in order to prevent dehydration of corrosion products in the crack tip, except during optical and photo-graphic measurement of crack lengths.
RESULTS Specimen Examinations Optical measurements of crack lengths were made on all the control U
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.
The specimens exposed to NS-1 suffered varying degrees of corrosion, and optical measurements of crack lengths were not possible because of the shallow depth of focus of the optical neasuring equipment, and air tool grinding of the side groove to reach base metal and achieve satisfactory delineation of the notch root and crack was required.
By agreement with Dow Nuclear Services, only a single specimen from 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.
Demineralized Water Control Exposure No evidence of crack propagation was observed on any of the specimens examined following exposure to demineralized water at 250 F for approximately 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br />.
A photograph of a typical crack is shown in Figure 1.
"Used" NS-1 Exposure Heavy attack was observed on the A335-P1 and A302-B specimens examined, as shown in Figures 2 and 3, and moderate attack was observed on the A106-B and A105 specimens as shown in Figures 4 and 5.
Measurements of crack lengths indicated significant increases for the first two alloys, but the in' ease in measured length was the result of general corrosion in the fatigue pre-crack crevice area rather than true crack extension. The calculated values for the corrosion were 0.08 inches for the A335-P1 and 0.05 inches for the A302-B.
As in the previous test series, only a single high-load specimen was selected for grinding and measurement.
Simulated BWR Exposures As stated previousl3., all specimens were exposed to three periods in 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, 8, and 9 Exposure to high temperature water appears to cause dissolution of the corrosion product from the initial NS-1 exposure, but not significant crack extension.
Optical and photographic crack length measurements were made on all three control specimens fron each heat of material, following each exposure period.
Photographic measurements were also made on the single ground high stress intensity specimens from each heat following each BWR ext ure.
The results of these measurements did not indicate significant effects of NS-1 on crack extension in subsequent BWR service.
However, some possible indication of such an effect was observed in data to be presented later in this report.
Fracture Surfaces Following the final simulated BWR exposure, one low stress intensity specimen from each heat of material was fractured at room temperature to assure that the crack length measurements which had been made were not seriously in error because of irregular crack front shape.
All sp ecimens exhibited straight crack fronts.
Two high s tress intensity specimens from each heat are still intact and in storage under 100% relative humidity conditions, and could be fractured if questions should arise at some later date.
Metallographic Examinations The single high stress intensity specimen from each heat of material which had one side-groove ground to permit crack length measurements throughout the simulated BWR exposures was sectioned through its midplane for metallographic examination af ter completion of the BWR exposure.
The results are shown in Figures 10,11,12, and 13.
Examination of the crack tips indicated that the NS-1 exposure resulted in a general blunting of the fatigue pre-crack.
However, there were indications of some subsequent crack propagation on the A105 specimen, as shown in Figure 13.
The fine nature of the cracks and the presence of oxide in the cracks indicates that this extension occurred during the subsequent BWR exposure, not during the NS-1 exposure. The apparent crack extension is approximately 0.018 inches; a value which is difficult to reliably detect using the photographic measurement method at a magnification of only 8.6 diameters, coupled with hand polishing. A single control specimen from this heat was sectioned at the mid-plane and evaluated metallographically, with the results shown in Figure 14.
No indications of crack propagation were observed on this specimen.
These results indicate the possibility of the presence of a deleterious effect on subsequent BWR service crack propagation resulting from exposure of A105 material to NS-1.
Two additional heats of A105 material are being evaluated in a subsequent run in order to determine if the observed behavior is representative of the alloy in general.
CONCLUSIONS The general effect of exposure of simulated cladding cracks on A335-P1, A302-B, A106-B, and A105 base materials appears to be some galvanic and crevice corrosion in the fatigue pre-crack, without significant crack extension during the cleaning cycle. No indications of crack extension in subsequent simulated BWR exposures were observed on single heats of A335-P1, A302-B, and A106-8 materials.
- However, indications of crack extension were observed on the A105 specimen exposed to N<-1, but not on a control specimen of the same alloy which had seen no NS-1 exposure.
These results indicate that the NS-1 exposure may have deleterious effects on crack extension in A105 material during subsequent service exposure.
However, the testing of additional heats of material and longer BWR exposure periods will be required to fM1y evaluate these results.
Additional heats of each of the four alloys discussed in this report will be exposed to NS-1 and subsequent simulated BWR environment in a third run which is currently in progress.
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