Alloy Design and Processing Challenges for Advanced Power Systems: an Alloy Producer’s Perspective


ISSN 1121-7588
Gernant E. Maurer, Ashish D. Patel
Carpenter Technology Corporation Bld.68, 101 W Bern St, Reading PA 19601 USA

Abstract

The alloys required for fossil fuel power systems are transitioning from stainless steels that operate below 600oC to nickel-based alloys that can operate up to 760oC in advanced ultra-super critical steam turbines. This transition brings with it major metallurgical as well as economic challenges related to alloy design, melt processing, and fabrication of these large size components. The alloys, in general, must maintain creep resistance over 100,000 hours of service life while at the same time maintaining resistance to severe steam oxidation and general oxidation. A need exists for nickelbased alloys that are not only highly alloyed, but are also impervious to phase instabilities during initial processing and service. The potential exists for severe segregation when casting large ingots. This possibility must be dealt with during thermo-mechanical processing to obtain the wrought structures that can be inspected to design defect levels.
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