Abstract
In this paper, predictions of creep crack initiation times and growth rates using the NSW-MOD model are compared with experimental data for the parent and weld metals of P91 at 600°C. For the weld metal, creep crack growth rates are found to be bounded by upper and lower bounds of the predictions, but creep crack initiation times are close to the upper bound. For the parent material, creep crack growth rates are bounded by upper and lower bounds of the predictions using the minimum creep rates, but creep crack initiation times are bounded by those using the average creep rates.
Keywords
Nomenclature
crack length and its incremental value
creep crack growth rate and its steady state value
creep strain rate constant
creep stress exponent
plastic hardening constant and exponent
Young’s modulus
limit load
reduction of area
rupture time and failure time
creep crack initiation time
specimen width
stress
normalized stress, see Eq. (8)
0.2% offset yield stress
tensile stress
plastic strain
normalized strain, see Eq. (8)
multiaxial creep ductility
creep ductility based on elongation
creep ductility based on reduction of area
power law creep strain rate
power law creep strain rate based on minimum creep
power law creep strain rate based on average creep
dimensionless equivalent strain, see Eq. (9)
creep process zone size at crack tip
crack tip angle
dimensionless integration constant, see Eqs (10a) and (10b)
Introduction
Creep crack growth properties are needed for assessing crack-like defects in high temperature components. Although such properties can be experimentally determined, testing often requires long time and thus predictive analytical/numerical tools would be quite useful. Nikbin et al. [1,2] proposed an analytical method to estimate upper and lower bounds of creep crack growth rates and creep crack initiation times, which is often referred to as the NSW model. The method is based on the ductility exhaustion concept incorporating the multi-axial stress effect on ductility. Using the NSW model, creep crack growth properties can be estimated solely from creep test data (idealised power-law creep properties and uni-axial ductility). Later the NSW model has been improved by considering angular variations of crack-tip stress and stress fields, which is often referred to as the modified NSW (NSW-MOD) model [3].
In literature, many researchers have applied the NSW and NSW-MOD models to predict creep crack growth rates and initiation times. For instance, Yatomi et al. [3] showed that the NSW model with average creep rates significantly overestimated the creep crack growth rates of a carbon–manganese steel at 360° but the NSW-MOD model gave more accurate upper bound prediction to the experimental data. Similar conclusions have been made for P92 welds at 650°C with minimum creep rates [4]. For Type 316H stainless steel at 525°C and 550°C, Dean and Gladwin [5] reported that experimental creep crack growth data was upper bounded by the NSW model using minimum creep rates. A more extensive test programme has been conducted on the same material at 550°C by Davies et al. [6,7], covering weld properties (parent material and heat-affected zone) and a range of specimen geometries at different temperatures. It was found that experimental creep crack growth rates overall lay between upper and lower bounds of the NSW-MOD prediction using minimum creep rates, and the initiation times were almost encompassed and close to the upper bound prediction. Above studies demonstrate that the NSW-MOD model gives better accuracy than the NSW model and application of appropriate creep properties (average or minimum) is important to the predictions of creep crack initiation times and growth rates.
The P91 martensitic steels have been used for high temperature components, for instance in ultra-supercritical fossil plants and more recently for structural components in Gen-IV reactors. As results, creep and creep-fatigue properties of P91 have been reported extensively in the literature (see for instance Refs [8–14]). Within research programs for developing Gen-IV reactors in Korea, short- and long-term creep crack growth tests of P91 were carried out for P91 parent and weld metals [15–17].
In this paper, the NSW-MOD model is applied to predict creep crack initiation times and growth rates of P91 at 600°C. A key issue to be resolved is “which power-law creep model (either minimum or average creep) gives better prediction for P91 parent and weld metals”. Section 2 presents tensile, creep and creep crack growth test results. Creep crack growth test results are compared with predictions using the NSW-MOD model in Section 3. Section 4 concludes the present work.
Tensile, creep and creep crack growth test data
Chemical compositions of the P91 plate (weight %)
Chemical compositions of the P91 plate (weight %)

(a) Engineering stress–strain curve from smooth bar test and (b) true stress–strain curve.
A commercial grade hot-rolled P91 martensitic steel was considered in this work. The chemical composition is listed in Table 1. Engineering stress–strain curve of the parent material is shown in Fig. 1(a) with a solid line. Yield (0.2% proof) and tensile strengths at 600°C were about 247.5 MPa and 362.7 MPa, respectively. True stress–strain curve at 600°C is shown in Fig. 1(b) with a solid line. True fracture strain, measured from reduction of area, was about 1.5. Engineering stress–strain data of the weld metal at 600°C is shown in Fig. 1(a) with a dotted line. Yield (0.2% proof) and tensile strengths at 600°C were about 298.2 MPa and 330.4 MPa, respectively. True stress–strain curve at 600°C is shown in Fig. 1(b) with a dotted line. True fracture strain, measured from reduction of area, was about 1.13.
Tensile properties of parent and weld metals of P91 at 600°C. For comparison, tensile properties of P91 parent material, given in RCC-MR [19], are also given
Tensile properties of parent and weld metals of P91 at 600°C. For comparison, tensile properties of P91 parent material, given in RCC-MR [19], are also given

(a) Comparison of experimental minimum creep rates with those in RCC-MR [19] and (b) experimental average creep rates.
Constant-load creep tests at 600°C were carried out with various stress levels ranging from 140 MPa to 180 MPa for the parent material and from 110 MPa to 160 MPa for the weld metal. From test data, constants for power-law creep can be fitted, as shown in Fig. 2. For the parent material, power-law creep properties based on minimum creep is given by
Summary of creep crack growth tests for the parent material and weld metal. Specimen dimensions: the width
Creep crack growth tests at 600°C were performed using a compact tension (C(T)) specimen. Sustained loads were ranged from 3.8 kN to 5.2 kN for the parent material, and from 3.5 kN to 4.5 kN for the weld metal. Creep crack growth test results of the parent and weld metals are summarized in Table 3 where applied sustained load P is normalized by a limit load for the plane strain C(T) specimen,

Experimental creep crack initiation times in terms of

Experimental crack growth rate data: (a) parent material and (b) weld metal.
Experimental creep crack growth rates for the parent metal are shown in Fig. 4(a) in terms of
When uni-axial creep properties are available, creep crack incubation times and growth rates can be predicted using the NSW-MOD model [3]. As the NSW-MOD model was developed for power law creep materials, a question arises on which power-law creep model (either minimum or average creep) gives better predictions for P91 parent and weld metals. This section investigates this issue.
NSW-MOD predictions for creep crack growth rates
Steady state creep crack growth rates in terms of
Summary of parameters in the NSW-MOD model
Figure 5 compares predicted creep crack growth rates using the NSW-MOD model with experimental data. Two estimates are shown; one using the minimum creep data (indicated by

Comparison of the experimental creep crack growth rates with NSW-MOD predictions: (a) parent and (b) weld metal.
Austin and Webster [21] have suggested that if the crack extension,
Figure 6 compares predicted creep crack initiation times corresponding to

Comparison of experimental creep crack initiation times with NSW-MOD predictions based on

Comparison of experimental creep crack initiation times with NSW-MOD predictions based on
This paper investigates applicability of the NSW-MOD model to predict creep crack initiation times and growth rates of P91 parent and weld metals at 600°C. From creep test data, power-law creep properties of P91 parent and weld metals are determined in two ways; based on minimum creep rates and average creep rates.
Experimental creep crack growth rates and initiation times are then compared with predictions using the modified NSW (NSW-MOD) model. The NSW-MOD predictions are made using either minimum or average creep rates, determined from creep tests. For the weld metal, predictions using the minimum creep rates are close to those using the average ones. Experimental creep crack growth rates are bounded by upper and lower bounds of the predictions, but experimental creep crack initiation times are close to the upper bound prediction. For the parent material, predictions using the minimum creep rates can be quite different from those using the average ones. Experimental creep crack growth rates are bounded by upper and lower bounds of the predictions using the minimum creep rates, but creep crack initiation times are bounded by those using the average ones.
Footnotes
Acknowledgements
This research was supported by National Research Foundation of Korea (NRF) funded by the Ministry of Science, ICT and Future Planning (NRF-2013M2B2B1075733, NRF-2007-0056094). The experimental data for the high-temperature tensile, creep, and creep crack growth tests used in this study were produced and supported by Korea Atomic Energy Research Institute (KAERI) and the authors would like to acknowledge with gratitude to KAERI.
