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• W2319503784 abstract "Future increases in the demand for clean and efficient electrical power production will be unrelenting. Meeting the coming challenges will require power generating systems capable of operating with increased boiler pressures and temperatures. In turn, meeting the demands of the application will also require materials which can withstand these extreme conditions. This paper describes a new nickel-base tubing alloy, INCONEL® alloy 740, developed for the purpose of meeting this challenge. This material possesses a unique combination of elevated temperature strength properties and resistance to coal ash corrosion required by the application. The material was developed to fulfill the minimum stress rupture requirement of 100,000 hour rupture life at a stress of 100 MPa and at a temperature of 750°C. In addition, metal loss of less than 2mm in 200,000 hours was defined as the target corrosion resistance for this material. The mechanical properties of this new material will be described, in addition to its coal ash and steam corrosion resistance and weldability. Thermal stability will also be discussed, focusing upon microstructural features of long-term exposed samples. Early methodology utilized to arrive at the current chemical composition will also be presented. INTRODUCTION When ultra supercritical steam conditions employing greater than 300 bar steam and 600°C steam temperature are adopted, it has been demonstrated that the efficiency of pulverized coalfired boilers can be increased to over 50% LHV (lower heating value). At this steam temperature, the superheater/reheater midwall temperature may be at 660°C or higher. At these metal temperatures, the conventionally used 9-12% Cr steels must be replaced by austenitic stainless grades. Projects like the European AD700 project and the German MARCKO DE2 project are planning for steam pressures up to 375 bar and steam temperatures to 700°C. This will lead to superheater/reheater mid-wall temperatures at over 740°C. Under these conditions, austenitic stainless steels cannot meet the stringent requirements of 100,000 hour rupture life at 750°C and 100 MPa and corrosion resistance defined as metal loss not exceeding 2mm after 200,000 hours. ALLOY DEVELOPMENT METHODOLOGY With no alloy in existence that could meet both the mechanical and corrosion demands of the described applications, an alloy development program was initiated. It was determined that the existing superalloy NIMONIC® alloy 263 possessed the required rupture strength but lacked the needed corrosion properties. This alloy was used as the basis for the development, utilizing additions of Cr and Nb for enhancement of corrosion resistance while maintaining the required volume percentage of gamma prime for precipitation hardening. ® INCONEL and NIMONIC are trademarks of the Special Metals Corporation group of companies. 601 Superalloys 718, 625, 706 and Derivatives 2005 Edited by E.A. Loria TMS (The Minerals, Metals & Materials Society), 2005 A rapid method of assessing rupture strength properties was utilized, involving testing samples and fixed stress of 100 MPa over a broad temperature range. Figure 1 shows a plot of collected data. The solid line represents the strength capability of NIMONIC alloy 263. Materials falling below that line were rejected from the program. Data shown for developmental alloys 1 and 2 fall above the alloy 263 data while data for alloy 3 lie well below. Figure 1. Plot showing rupture life in hours versus temperature in degrees Celcius. The solid line is the isocline for NIMONIC alloy 263. The data points shown represent experimental materials evaluated in the alloy development program. Figure 2 shows the results of predictions made using Thermo-Calc of the atomic percentage of gamma prime as a function of Al and Ti content. The chart was constructed by mapping interpolated data. A minimum percentage of 15% was deemed acceptable. Assessment of preliminary data acquired to evaluate mechanical and corrosion properties of developmental heats of INCONEL alloy 740 resulted in the nominal composition shown in Table 1 being established. Nominal composition for other alloys mentioned in this study are included as well. 1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 750 800 850 900 950 Temperature, °C R u p tu re L if e , H o u rs 1" @default.
• W2319503784 created "2016-06-24" @default.
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• W2319503784 date "2005-01-01" @default.
• W2319503784 modified "2023-09-23" @default.
• W2319503784 title "A New Alloy Designed for Superheater Tubing in Coal-Fired Ultra Supercritical Boilers" @default.
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• W2319503784 doi "https://doi.org/10.7449/2005/superalloys_2005_601_611" @default.
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