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CREEP 1
Creep is the time-dependent deformation which occurs at elevated temperature
when materials are subjected to stress.
Most engineering components are designed on the basis that strength has a constant
value for a particular material, and that the strain is instantaneous and remains
constant with time on the application of a given load. As operating temperature
increases, the tensile properties (ultimate tensile strength and yield strength)
generally decrease but strain continues to be essentially instantaneous when load is
applied. At higher temperatures materials show an additional strain the creep strain
- which gradually increases with time even under constant load. Ultimately, the creep
deformation will lead to fracture of the component. A related phenomenon is stress
relaxation. This is the reduction in load which occurs with time when the strain of
certain components is kept constant. An example is bolts holding together high
temperature components which need to be periodically retightened because of load
relaxation.
Main engineering areas where creep can be significant are fossil-fuel and nuclear
power plant (boilers, pipework and steam turbines), chemical plant, and aero-engines.
Since thermodynamic efficiencies increase with increasing temperature, technological
advances in these and other areas often involve higher operating temperatures.
Furthermore, operating lifetimes are continually being increased. Detailed knowledge
of creep behaviour is therefore essential for safe and economic design of critical
components and structures.
Comparison of metals
Creep behaviour is categorised according to the temperature relative to the melting
point of a metal: Th = T / Tm (in K) - the homologous temperature.
Material
Melting temp, Tm
C
0.3 TmC
0.5 TmC
Th (=T/Tm) achieved
in alloys
lead (Pb)
320
600
- 93
27
aluminium (Al)
660
933
194
copper (Cu)
1083
1356
134
405
steels
~1400
~1673
229
564
stainless steels
~1450
~1723
244
589
nickel (Ni)
1453
1726
245
590
titanium (Ti)
1668
1941
309
698
~0.4
50
tungsten (W)
3380
3653
823
1554
Different metals have similar creep characteristics when tested at the same Th.
general, creep deformation is not significant at temperatures below ~0.3 Tm.
In
Plastics also exhibit creep, which may be significant at ambient temperatures. Creep
of plastics is not covered in this module.
Types of creep failures
excessive deformation - pipework, gas or steam turbine blades;
creep buckling - deformation under compressive load;
creep cracking - pipework and pipework welds;
creep rupture - rupture of tungsten filament in an incandescent light bulb;
interactions - between creep and fatigue;
- between creep and environmental degradation; etc
Creep and stress-rupture testing
In metals, the majority of creep data are
collected
using
tensile
specimens
constant
load
tests
(dead-
testing
the
only
data
In standard
It should be noted that the popular constant-load test does not give precisely
constant-stress conditions, and for the most detailed understanding and verification of
creep theories truly constant-stress equipment is used. These use devices (e.g.
profiled cam) to adjust the load on the specimen as a function of measured strain,
assuming uniform deformation and constant volume. However, provided the creep
51
ductility of the material is low, say, only a few percent total creep strain, the results
from constant-load and constant-stress test methods are practically identical.
A typical creep curve of strain against time (linear scales) can be divided into three
regions:
III
D
II
I
c
B
t
A
After the initial immediate elastic extension i, there is primary creep BC (or transient
creep) in which the strain rate decreases with time. This is followed by secondary
creep CD in which the creep rate is constant with time. This is the steady-state strain
rate. Finally there may be tertiary, or accelerating, creep leading to fracture at E,
otherwise known as creep rupture or stress rupture. The total strain at rupture is
typically only a small fraction of the elongation to fracture in a tensile test at the same
temperature. The strain due to creep is c. If the specimen is unloaded at any point on
the curve there is an immediate recovery of strain, according to Hookes Law, but
negligible subsequent recovery.
The details of the c vs t curve are sensitive to alloying composition, including trace
elements in some cases; grain size; heat treatment; previous stress history; and
environment as well as temperature; applied stress and stress state.
1 < 2 < 3
= Fracture
3
2
2
1
(a)
(b)
52
Interstitial diffusion
Small atoms (e.g. C and N in steel)
can diffuse by squeezing through
the space between larger atoms.
Vacancy diffusion
Interstitial
diffusion
(b)
Vacancy
diffusion
(b)
53
Gra
in
bou
nda
Diagrammatic representation
ry
n da
ry
In the absence of stress, the direction in which atoms (or vacancies) diffuse is
governed by their concentration. They move from the more concentrated regions to
the less concentrated regions, or may be chemically attracted by other species to form
precipitates (e.g. Ti + C). The stress system also influences the direction of the
movement of the atoms or vacancies. Time dependent deformation (i.e. creep)
therefore occurs.
This is called diffusion creep and it is the dominant creep
mechanism at high temperatures (T/Tm > 0.4) and low stresses.
There are two main categories of diffusion creep: at the highest temperatures
diffusion in the bulk of the lattice, known as Nabarro-Herring creep, is rapid and
diffusion along the grain boundaries and dislocations makes negligible contribution.
However, as temperatures decrease towards 0.4Tm, diffusion along the easy paths
becomes progressively more significant because of their lower activation energies.
Dominance by grain boundary diffusion is called Coble creep.
Dislocation creep
At any temperature, creep also occurs by the movement of
dislocations provided the stresses are sufficiently high. This can be by the same
mechanism that plastic flow occurs under high load at ambient temperature (see
sketch). Other processes of dislocation movement are also activated at elevated
temperature.
54
(a)
(b)
(c)
Note: the three regions of the typical creep curve do not represent three different
mechanisms, but rather the result of competing effects:
Strain hardening caused by dislocation movement results in strain hardening
(multiplication and tangling of dislocations which make subsequent dislocation
movement more difficult);
Recovery enabled by diffusion processes (loss of dislocations making subsequent
deformation easier).
55
The high temperature creep curve thus shows a linear portion where rates of
hardening and recovery balance.
At low temperatures, the creep curve may show a continuously decreasing gradient,
because of strain hardening which is not removed by recovery. This is also called
logarithmic creep.
Creep resistant alloys
For a material to withstand creep at high temperatures, a high melting point is
desired. Ceramics are sometimes used for this reason, but some of the most
refractory metals (e.g. tungsten and niobium) have limited use because they are
manufactured by a powder route. Oxidation resistance is another requirement.
The most commonly used creep resistant alloys are based on iron or nickel. Increases
to creep resistance are achieved by alloying additions and heat treatments to provide
extra strengthening: in particular fine dispersions of precipitates are effective in
restricting dislocation movement.
The precipitates must be stable at high
temperature, with minimal tendency to coarsen. The Nimonic alloys are some of the
most advanced creep-resisting alloys they contain chromium for oxidation
resistance, and complex precipitates based on Ni3 (Ti, Al).
Further improvements to creep resistance are achieved by using directional
solidification or single crystal components, to minimise the number of grain
boundaries lying normal to the load. This reduces the degree of grain boundary creep.
For example: Ni-based gas turbine blades.
Representations of creep behaviour
high , high T
Low , high T
t
56
For design purposes, predictions of the long-term creep strain under the operating
conditions of stress and temperature are required. A typical design standard requires
the stress to give minimum creep rates of 1% strain in 10,000 hours, or 1% strain in
100,000 hours. It is impractical to derive direct data from all possible combinations of
loading parameters, and to carry out numerous tests lasting these times. In other
applications predictions at even greater times are needed for example 300,000
hours for parts of power station boilers, pipework and steam turbines. Accelerated
tests at either higher stress or higher temperature must therefore be performed and
the results extrapolated to longer times. This must be done with caution!
For low-temperature creep, occurring at <0.3Tm, it is found that the transient creep
strain vs time can be expressed by
c 1 ln( 2 t 1) ,
c 1 2
2t 1
Q
f 2 (T) exp
RT
where
For T >> 0.4Tm, Q is found experimentally to be close to the activation energy for
lattice self-diffusion expected.
(steady-state creep)
f3 (t) = b tm
(Bailey)
f3 (t) = (1 + b t1/3)ekt -1
(Andrade)
mj
f3 (t) = a j t
A combination of the Bailey model and steady state is also often used, i.e.
f3 (t) = t + b tm
this being capable of representing primary and steady-state creep.
NB: Primary creep is sometimes included as part of the initial strain.
Stress dependence
By plotting a series of creep curves at the same temperature but with different
stresses, the relationship between strain rate and stress can be explored. Various
equations have been used to represent the stress dependence, f1 (), of the secondary
creep behaviour.
SS
= An
(Norton)
SS
= B sinh ()
(Prandtl)
SS
= C [sinh ()]p
(Garofalo)
SS
= D ( o)q
(friction stress)
Because of its simplicity in mathematical analysis, the Norton equation is the most
commonly used.
SS
= An
(Norton)
It can be rewritten:
log (
SS
) = log A + n log ()
Nortons Law provides the basis for the power law relationships which have been
widely used to describe high-temperature creep behaviour. The stress exponent, n, is
an important creep property.
To obtain n values, creep curves are recorded at the same temperature but at
ss
different stresses. The secondary creep rates, , are plotted against on a log-log
scale. This can be repeated for tests at different temperatures. It is found that n
varies between 3 and 10 under the most common conditions used for creep tests but
at low stress n ~ 1.
A simple overall equation for the rate of steady state (secondary) creep can therefore
be of the form:
d css
d ( f 3 (t ))
f1 ( ). f 2 (T ).
dt
dt
For example, the power law expression often fits experimental data quite well and is
commonly used:
SS = C. n. exp[ Q ]
RT
This is likely to be valid within limited ranges of stress and temperature when n and Q
are constant i.e. the same physical mechanisms are occurring.
Tertiary creep and fracture
Creep at low temperatures very rarely leads to failure, and little change in
microstructure is evident apart from plastic strain. Creep at high temperatures almost
always leads to fracture, and the onset of fracture is indicated by the acceleration of
creep strain rate in the tertiary region.
Creep fracture data are usually presented as log () vs. log (tf) and
f vs log (tf).
59
Ductility usually tends to decrease with increasing test duration (although this is not
always the case). The log () vs log (tf) and f vs log (tf) data are usually of the form:
Log
Ductile failure
Load
Intergranular crack
Brittle failure
Material
Grain
Grain boundary
Log tf
(a)
Transgranular means the fracture path runs across
the bulk of grains; intergranular
means it runs along grain boundaries.
Load
Load
Intergranular crack
Grain boundary
Grain boundary
Material
Grain
Material
Grain
Transgranular crack
(b)
(a)
Mechanisms of failure
Load
Transgranular crack
60
(b)
o,
lo , l
Ao, A
F
Failure life for ductile creep
0 0
Constant volume:
= =
Equilibrium:
= =
Nortons law:
0 0
0 0
= = (
(1)
= (
0 0
= (
) =
(2)
(1) = (2)
1
1
0
= , so
1 = 0
0
0 0
1
0
= (
]
[
1(
(3)
when 0, , So
=
i.e.
(4)
0
1
= ( ) (slope = - 1/n)
61
Failure mechanisms:
Transgranular cracking;
Necking (area reduction);
Voids nucleation is weak.
(ii) Brittle-failure
Brittle creep fracture occurs because voids nucleate and grow (mainly at the grain
boundaries), and grain boundaries crack and slide due to the increases in stress in
those regions as creep occurs.
Voids and cracks tend to grow on boundaries which, are perpendicular to the stress
axis. These effectively reduce the load-bearing cross-sectional area.
The damage, , is defined as the ratio of the area of voids, Av, at any cross sectional
area to the overall cross-sectional area, Ao, i.e.
Av
A
or 1
Ao
Ao
= (
= (
)
1
)
1
(1)
(2)
62
Av (voids)
0 (1 ) = 0
i.e.
Ao
(1)+1
+1
] = ,
0
(1 ) = [1 ( + 1) ]+1
(3)
when 1,
therefore,
(4)
(+1)
Creep strain
Substituting (3) (1)
0 = 0 [1 ( + 1) ]
()
(+1)
{1 [1 ( + 1)
+1
+1
] +1
From (4)
) (slope = - 1/)
(+1)
= (
63
After creep failure has occurred, fracture surfaces often show grain facets, sometimes
with dimples, and they may be oxidised from exposure to high temperature.
A1
A3
A2
600oC
550oC
500oC
Log tf
Log
Master Curve
600oC
550oC
PLM (T, tf)
is
is
is
is
PLM ()
Test conditions
time, h
temp, C
8
500
PLM
~ 16152
65
10 000
1 000
400
500
219
40
450
550
~ 16152
~ 17779
A variation of the Larson-Miller parameter (putting C = 23.3 for better fit) employed to
superimpose results for a low alloy steel used for steam pipework (from Evans &
Wilshire Introduction to Creep). Test temperatures from 500 to 600C are
superimposed.
Use of the Larson-Miller parameter to compare qualitatively the performance of
different materials.
66
3
Firstly, experimental results indicate that creep is a constant volume process, i.e.
1c 2c 3c 0
The condition also implies that hydrostatic stress states (i.e. 1 = 2 = 3) do not
cause any creep strains to occur. If 1 = 2 = 3 , from symmetry and assuming the
material is isotropic,
1c 2c 3c ,
1c 0 , hence 2c 3c 0
1c 2c 3c 0 ,
and since,
then 3 1
0,
i.e.
too.
The results of experimental tests also indicate that the superposition of a hydrostatic
stress state onto any other stress state does not influence the creep behaviour.
O (Hydrostatic
axis)
P (, , )
O (m, m, m)
hydrostatic component (m , m ,
O
2
m
m
67
( 1 2 3 )
3
eff K1 ( 1 2 ) 2 ( 2 3 ) 2 ( 3 1 ) 2
The value of K1 can be determined by considering the uniaxial stress state, i.e. 1 0,
2 = 3 = 0. Under these conditions, 1 = eff
Therefore, K1 ( 1 0) 0 (0 1 )
2
Thus K1
K1 2. 1 = eff
1
2
eff
1
2
( 1 2 ) 2 ( 2 3 ) 2 ( 3 1 ) 2
ceff K 2 ( 1c c2 ) 2 ( c2 3c ) 2 ( 3c 1c ) 2
This must also reduce to the uniaxial form, i.e.
K 2 ( (
c
1
c
1
1c
2
)) 0 (
2
1c
2
c
eff
1c when 1 0 but 2 = 3 = 0.
2c 3c 1c / 2
when 2 = 3 = 0,
1c ) 2
ie K2 = 2/3
ceff
2
( 1c c2 ) 2 ( c2 3c ) 2 ( 3c 1c ) 2
3
= f1 () f2 (t),
68
c
It is also necessary to define a flow rule, ie we need to be able to split eff into its
component parts. The flow rule must contain the constant volume condition and the
fact that the hydrostatic stress component does not affect creep behaviour.
If we subtract the hydrostatic stress components from each of the stress components
(1, 2 and 3) we obtain the components of 0''P in the 1, 2 and 3 directions, ie ( 1m), (2- m) and (3- m). If the creep strain rates in the 1, 2 and 3 directions are
proportional to these components of 0''P, the sum of the components must be zero, ie
K3 (1- m) + K3 (2- m) + K3 (3- m) must be zero.
Now , m
(1 2 3 )
3
and
= K3 (1- m)
= K3 (2- m)
= K3 (3- m)
Again the value of K3 can be obtained by considering the behaviour under a uniaxial
stress condition: 1 0 but 2 = 3 =0, hence eff = 1 and eff
eff
= 1 . So,
c
1
2
1) =
K3 1
3
3
69
3 ceff
.
2 eff
1
2
3 ceff
ceff
1
( 1 m ) =
(1 (2 3 ))
=
2 eff
eff
2
ceff
1
(
(3 1 ))
=
2
eff
2
ceff
1
(
(1 2 ))
=
3
eff
2
c
eff
Substituting
where eff
f1 ( eff )
eff
( 1
f1 ( eff )
eff
1
( 2 ( 3 1 )). f 2 (t )
2
f1 ( eff )
eff
1
2
1
( 2 3 )). f 2 (t )
2
1
( 3 ( 1 2 )). f 2 (t )
2
( 1 2 ) 2 ( 2 3 ) 2 ( 3 1 ) 2
The multiaxial creep law can be further generalised to include shear stresses and
strains.
f1 ( eff )
1
( x ( y z )).f 2 ( t )
eff
2
f1 ( eff )
eff
f1 ( eff )
eff
( y
1
( z x )). f 2 (t )
2
( z
1
( x y )). f 2 (t )
2
70
f1 ( eff )
xz 3
.
yz
( eff )
xy 3
f1 ( eff )
( eff )
f1 ( eff )
( eff )
. xz . f 2 (t )
. yz . f 2 (t )
. xy . f 2 (t )
where
eff
1
2
zz
zy
zx
xz
yz
xy
yy
yx
xx
71