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Research Papers: Materials and Fabrication

Numerical Simulation of Damage Evolution and Life Prediction for Two Commercial Fe–Cr–Ni Alloys Subjected to Mechanical and Environmental Factors

[+] Author and Article Information
Limin Shen

School of Chemical Engineering
and Technology,
China University of Mining and Technology,
Xuzhou 221116, China
e-mail: shenlm@cumt.edu.cn

Peibin Jin

School of Chemical Engineering
and Technology,
China University of Mining and Technology,
Xuzhou 221116, China
e-mail: jpb1521299@163.com

Yanfei Wang

School of Chemical Engineering
and Technology,
China University of Mining and Technology,
Xuzhou 221116, China
e-mail: wyf_hg@cumt.edu.cn

Jianming Gong

College of Mechanical and Power Engineering,
Nanjing Tech University,
Nanjing 211816, China
e-mail: gongjm@njtech.edu.cn

1Corressponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received November 2, 2015; final manuscript received February 23, 2016; published online April 29, 2016. Assoc. Editor: Kunio Hasegawa.

J. Pressure Vessel Technol 138(5), 051403 (Apr 29, 2016) (7 pages) Paper No: PVT-15-1245; doi: 10.1115/1.4032916 History: Received November 02, 2015; Revised February 23, 2016

Associated with mechanical and environmental degradation, such as low-oxygen potential, high carbon activity, and high operating temperature, premature failure generally occurs in ethylene cracking furnace tube. This work is aimed at damage evolution numerical simulation and life prediction of two commercial Fe–Cr–Ni alloys (HP40Nb alloy and KHR45A alloy) under different operating temperatures, subjected to coupled carburization damage and creep damage. The results show that carburization is the most important factor that caused ethylene cracking furnace tube to rupture ahead of service time. Increased operating temperatures accelerate the damage rate markedly for the two alloys. For HP40Nb alloy and KHR45A alloy, the service life at 1223 K is almost 2.5 and 3 times higher than the value at 1323 K, respectively. Due to a higher mass of Ni/(Cr + Fe) ratio, the service life of KHR45A alloy is longer than that of HP40Nb alloy at the same operating condition. Distribution of von Mises stress σe and maximum principal stress σp along the inner surface and the outer surface of tubes is different to each other with damage evolution at different operating temperatures.

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Figures

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Fig. 1

Geometric structure and meshing of the damage model: (a) geometry structure and (b) mesh of the model

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Fig. 2

von Mises stress σe (a) and maximum principal stress σp (b) nephogram of KHR45A alloy at 1323 K operating for 0 hr

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Fig. 3

von Mises stress σe (a) and maximum principal stress σp (b) nephogram of KHR45A alloy at 1223 K operating for 0 hr

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Fig. 4

Distribution nephogram of damage value SDV1 (a), von Mises stress σe (b), and maximum principal stress σp (c) of KHR45A alloy after operating for 91,500 hrs at 1323 K

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Fig. 5

Distribution nephogram of damage value SDV1 (a), von Mises stress σe (b), and maximum principal stress σp (c) of KHR45A alloy after operating for 271,000 hrs at 1223 K

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Fig. 6

Variation of damage evolution versus time of KHR45A alloy at 1323 K (a) and 1223 K (b)

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Fig. 7

Variation of von Mises stress evolution of KHR45A steel tube at 1323 K (a) and 1223 K(b)

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Fig. 8

Variation of maximum principal stress evolution of KHR45A steel tube at 1323 K (a) and 1223 K (b)

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Fig. 9

Variation of damage evolution of HP40Nb alloy tube at 1323 K (a) and 1223 K (b)

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Fig. 10

Variation of von Mises stress evolution of HP40Nb alloy tube at 1323 K (a) and 1223 K(b)

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Fig. 11

Variation of max principal stress evolution of HP40Nb alloy tube at 1323 K and 1223 K

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