Microstructural evolution of a steam-turbine rotor subjected to a water-quenching process: numerical simulation and experimental verification

• Chuan Wu
• Qing-Ling Meng
Article

Abstract

Cr-Ni-Mo-V steam-turbine rotors have been widely used as key components in power plants. In this study, a coupled thermomechano-metallurgical model was proposed to simulate the phase transformation and transformation-induced plasticity (TRIP) of a 30Cr2Ni4MoV steam-turbine rotor during a water-quenching process, which was solved using a user defined material mechanical behavior (UMAT) subroutine in ABAQUS. The thermal dilation, heat generation from plastic work, transformation latent heat, phase transformation kinetics, and TRIP were considered in the model. The thermomechanical portion of the model was used to predict the evolution of temperature, strain, and residual stress in the rotor. The phase transformation that occurred during the quenching process was considered. Constitutive models of phase transformations (austenite to pearlite, austenite to bainite, and austenite to martensite) and TRIP were developed. Experimental data were adopted and compared with the predicted results to verify the accuracy of the model. This demonstrates that the model is reliable and accurate. Then, the model was utilized to predict the temperature variation, dimensional change, minimum austenitization time, residual stress, TRIP, and volume fractions of each phase. It is concluded that this model can be a useful computational tool in the design of heat-treatment routines of steam-turbine rotors.

Keywords

Thermomechano-metallurgical model user defined material mechanical behavior (UMAT) subroutine Microstructural evolution Transformation-induced plasticity (TRIP) Residual stress

Notes

Acknowledgements

The authors would like to gratefully acknowledge the support of the Scientific Research Foundation of Tianjin University of Technology and Education (Grant No. KYQD1801). We appreciate Mr. Hua-Nan Jiang’s contribution to the thermo-mechanical constitutive models in this work.

References

1. 1.
Chen F, Cui ZS, Sui DS et al (2012) Recrystallization of 30Cr2Ni4MoV ultra-super-critical rotor steel during hot deformation Part III: Metadynamic recrystallization. Mater Sci Eng A 540:46–54
2. 2.
Zhou P, Ma QX, Luo JB (2017) Hot deformation behavior of as-cast 30Cr2Ni4MoV steel using processing maps. Metals 7:1–12
3. 3.
Xin RS, Luo JB, Ma QX (2017) Effect of parameters on internal crack healing in 30Cr2Ni4MoV steel for 600-ton ultra-super ingots. Metals 7:149–161
4. 4.
Chen F, Cui ZS, Chen SJ (2011) Recrystallization of 30Cr2Ni4MoV ultra-super-critical rotor steel during hot deformation. Part I: Dynamic recrystallization. Mater Sci Eng A 528:5073–5080
5. 5.
Boccardo AD, Dardati PM, Celentano DJ et al (2017) Austempering heat treatment of ductile iron: computational simulation and experimental validation. Finite Elem Anal Des 134:82–91
6. 6.
Vasconcelos P, Gießmann A, Dias-de-Oliveira J et al (2015) Heat treatment analysis of multiphase steels through the use of a coupled phase field and finite element model methodology. Comput Mater Sci 107:139–150
7. 7.
He QQ, Sun J, Yan CX et al (2013) Thermo-mechanical modeling and simulation of microstructure evolution in multi-pass H-shape rolling. Finite Elem Anal Des 76:13–20
8. 8.
Chen F, Cui ZS, Liu J et al (2010) Mesoscale simulation of the high-temperature austenitizing and dynamic recrystallization by coupling a cellular automaton with a topology deformation technique. Mater Sci Eng A 527:5539–5549
9. 9.
Chen F, Cui ZS, Liu J et al (2009) Modeling and simulation on dynamic recrystallization of 30Cr2Ni4MoV rotor steel using the cellular automaton method. Model Simul Mater Sci Eng 17:1–19
10. 10.
Chen SW, Liu HM, Peng Y et al (2013) Trip layer method for simulation of the three-dimensional deformations of large cylindrical shell rolling. Int J Mech Sci 77:113–120
11. 11.
Chen SW, Liu HM, Peng Y et al (2014) Slab analysis of large cylindrical shell rolling. J Iron Steel Res Int 21:1–8
12. 12.
Zheng CW, Raabe D (2013) Interaction between recrystallization and phase transformation during intercritical annealing in a cold-rolled dual-phase steel: a cellular automaton model. Acta Mater 61:5504–5517
13. 13.
Zheng CW, Raabe D, Li DZ (2012) Prediction of post-dynamic austenite-to-ferrite transformation and reverse transformation in a low-carbon steel by cellular automaton modeling. Acta Mater 60:4768–4779
14. 14.
Taleb L, Petit S (2006) New investigations on transformation induced plasticity and its interaction with classical plasticity. Int J Plast 22:110–130
15. 15.
Dutta RK, Amirthalingam M, Hermans MJM et al (2013) Kinetics of bainitic transformation and transformation plasticity in a high strength quenched and tempered structural steel. Mater Sci Eng A 559:86–95
16. 16.
Lambers HG, Canadinc D, Maier HJ (2012) Evolution of transformation plasticity in austenite-to-bainite phase transformation: a multi-parameter problem. Mater Sci Eng A 541:73–80
17. 17.
Zhang W, Elmer JW, Debroy T (2002) Kinetics of ferrite to austenite transformation during welding of 1005 steel. Scripta Mater 46:753–757
18. 18.
Azghandi SHM, Ahmadabadi VG, Raoofian I et al (2015) Investigation on decomposition behavior of austenite under continuous cooling in vanadium microalloyed steel (30MSV6). Mater Des 88:751–758
19. 19.
Hehemann RF, Troiano AR (1956) The bainite transformation. Metal Progress 70:97–104Google Scholar
20. 20.
Davenport E, Bain E (1970) Transformation of austenite at constant subcritical temperatures. Metall Mater Trans B 1:3503–3530
21. 21.
Bhadeshia HKDH, Edmonds DV (1980) The mechanism of bainite formation in steels. Acta Metallurgica 28:1265–1273
22. 22.
Chen RK (2013) Investigation on the heat treatment processing of 30Cr2Ni4MoV rotor. Dissertation, Shanghai Jiao Tong UniversityGoogle Scholar
23. 23.
Chen RK, Gu JF, Han LZ et al (2013) Austenitization kinetics of 30Cr2Ni4MoV steel. Trans Mater Heat Treat 34:170–174Google Scholar
24. 24.
Barbier D (2014) Extension of the martensite transformation temperature relation to larger alloying elements and contents. Adv Eng Mater 16:122–127
25. 25.
Taleb L, Cavallo N, Waeckel F (2001) Experimental analysis of transformation plasticity. Int J Plast 17:1–20
26. 26.
Taleb L, Sidoroff F (2003) A micromechanical modeling of the Greenwood-Johnson mechanism in transformation induced plasticity. Int J Plast 19:1821–1842
27. 27.
Taleb L, Petit S (2006) New investigations on transformation induced plasticity and its interaction with classical plasticity. Int J Plast 22:110–130
28. 28.
Mittemeijer EJ (1992) Analysis of the kinetics of phase transformations. J Mater Sci 27:3977–3987
29. 29.
Van Genderen M, Isac M, Böttger A (1997) Aging and tempering behavior of iron-nickel-carbon and iron-carbon martensite. Metall Mater Trans A 28:545–561
30. 30.
Coret M, Calloch S, Combescure A (2002) Experimental study of the phase transformation plasticity of 16MND5 low carbon steel under multiaxial loading. Int J Plast 18:1707–1727
31. 31.
Kwak SY, Hwang HY (2018) Effect of heat treatment residual stress on stress behavior of constant stress beam. J Comput Des Eng 5:137–143Google Scholar
{"extraction_info": {"found_math": false, "script_math_tex": 0, "script_math_asciimath": 0, "math_annotations": 0, "math_alttext": 0, "mathml": 0, "mathjax_tag": 0, "mathjax_inline_tex": 0, "mathjax_display_tex": 0, "mathjax_asciimath": 0, "img_math": 0, "codecogs_latex": 0, "wp_latex": 0, "mimetex.cgi": 0, "/images/math/codecogs": 0, "mathtex.cgi": 0, "katex": 0, "math-container": 0, "wp-katex-eq": 0, "align": 0, "equation": 0, "x-ck12": 0, "texerror": 0, "math_score": 0.8253248929977417, "perplexity": 29125.059879689907}, "config": {"markdown_headings": false, "markdown_code": true, "boilerplate_config": {"ratio_threshold": 0.18, "absolute_threshold": 10, "end_threshold": 15, "enable": true}, "remove_buttons": true, "remove_image_figures": true, "remove_link_clusters": true, "table_config": {"min_rows": 2, "min_cols": 3, "format": "plain"}, "remove_chinese": true, "remove_edit_buttons": true, "extract_latex": true}, "warc_path": "s3://commoncrawl/crawl-data/CC-MAIN-2019-09/segments/1550247487595.4/warc/CC-MAIN-20190218155520-20190218181520-00570.warc.gz"}