Astm stp 1259 1997

STP 1259 Steel Forgings: Second Volume Edward G Nisbett and Albert S Melilli, editors ASTM Publication Code Number (PCN): 04-012590-02 ASTM 100 Barr Harbor Drive West Conshohocken, PA 19428-2959 Printed in the U.S.A Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Library o f Congress C a t a ] o g l n g - l n - P u b t i c a t | o n Data Steel forglngs Second v o ] u m e / [ e d l t e d by] Edward G N l s b e t t and A l b e r t S H e ] i ] ] i p, cm, " C o n t a i n s p a p e r s p r e s e n t e d a t t h e Second Symposium on S t e e ] F o r g i n g s h e ] d in New O r ] e a r s , L o u l s l a n a , on November - , 1996 s p o n s o r e d by ASTM C o m m i t t e e A-1 on S t e e l , S t a i n l e s s S t e e ] , and Related Al]oys" P iii "STP " "ASTM p u b l i c a t i o n code number (PCN) - - " Inc]udes bib]iographlca] r e f e r e n c e s and l n d e x ISBN - - - S t e e l f o r g i n g s - - C o n g r e s s e s I N l s b e t t , Edward G II Me]l]]l, A l b e r t S III A m e r l c a n S o c l e t y f o r T e s t i n g and Haterials Committee A-1 on S t e e ] , S t a l n ] e s s S t e e l , and R e l a t e d Al]oys TS320.$744 1997 672.3'32 dc21 97-22639 CIP Copyright 1997 AMERICAN SOCIETY FOR TESTING AND MATERIALS, West Conshohocken, PA All rights reserved This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film, or other distribution and storage media, without the written consent of the publisher Photocopy Rights Authorization to photocopy items for internal, personal, or educational classroom use, or the internal, personal, or educational classroom use of specific clients, is granted by the American Society for Testing and Materials (ASTM) provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; Tel: (508) 750-8400; online: http://www.copyright.com/ Peer Review Policy Each paper published in this volume was evaluated by two peer reviewers and at least one of the editors The authors addressed all of the reviewers' comments to the satisfaction of both the technical editor(s) and the ASTM Committee on Publications To make technical information available as quickly as possible, the peer-reviewed papers in this publication were prepared "camera-ready" as submitted by the authors The quality of the papers in this publication reflects not only the obvious efforts of the authors and the technical editor(s), but also the work of these peer reviewers The ASTM Committee on Publications acknowledges with appreciation their dedication and contribution of time and effort on behalf of ASTM Printed in Fredericksburg, VA 1997 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Foreword This publication, Steel Forgings: Second Volume, contains papers presented at the Second Symposium on Steel Forgings in Hyatt Regency New Orleans, New Orleans, Louisiana, on November 20-2 I, 1996 The symposium was sponsored by ASTM Committee A-1 on Steel, Stainless Steel, and Related Alloys The symposium was chaired by E G Nisbett, National Forge Company; A S Melilli, Consultant, Winchester They also served as editors of this publication Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Contents Overview vii PRESSURE VESSEL AND NUCLEAR FORGINGS New Materials and Forgings Used for Pressure Vessels Operating in Hydrogen Environment P BOCQUET, A CHEVIET, L COUDREUSE AND R DUMONT Improved Mechanical Properties of the A 508 Class Steel for Nuclear Pressure Vessel Through Steelmaking JEONG-TAE KIM,HEEKYUNGKWON,KOOK-CHULKIM,ANDJOONG-MYOUNGKIM 18 Effects of Composition and Heat Treatment on the Toughness of ASTM A508 Grade Class Material for Pressure VesselsmMINFA LIN, STEVEN S HANSEN, TODD D NELSON, AND ROBERT B FOCHT 33 Current Forgings and Their Properties for Steam Generator of Nuclear P l a n t ~ H I S A S H I TSUKADA, KOMEI SUZUKI, MIKIO KUSUHASHI, AND IKUO SATO 56 Forging Technology Adapted to the Manufacture of Nuclear PWR Austenitic Primary P i p i n g - - F R A N C O I S E MORIN, PIERRE BOCQUET, AND ALAIN CHEVIET 65 The Optimization of Mechanical Properties for Nuclear Transportation Casks in ASTM A350 LF5~STEPHEN PRICEANDGRAHAMA HONEYMAN 79 GENERAL INDUSTRIAL FORGINGS Developments in Forging Ingot Production at Bethforge I n c q JOHN E FIELDING, ROBERT B FOCHT, KENNETH F REPPERT, AND EUGENE L TIHANSKY 93 Application of Nitrogen-Alloyed Martens~dc Stainless Steels in the Aviation Industry GERALD STEIN,WALTERKIRSCHNER,AND JOACHIMLUEG 104 Process Model Development for Optimization of Forged Disk Manufacturing Processes CHRISTIAN E FISCHER,JAYS GUNASEKERA,AND JAMESC MALAS 116 Manufacturing and Properties of Continuous Grain Flow Crankshafts for Locomotive and Power Generation Diesel EngineSqDANiEL J ANTOS AND EDWARD G NISBETF Reducing Stress Related Problems in Steel Forgings Using Sub-Harmonic Vibrational Energy THOMAS E HEBEL 129 148 Development of a Process for Toughening Grain-Refined, High-Strength S t e e l s - - M I C H A E L J LEAP, JAMES C WINGERT, AND CHARLES A MOZDEN 160 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized The Chemistry Modifications to ASTM A707 for Offshore Structural Integrity MARTIN A WALSHAND STEPHENPRICE 196 TEST METHODS Ultrasonic Signal Processing Using Indication Sets for Detection and Charaeterization~JOHN R M VIERTL 213 Application of Fem-Based Modeling of Open-Die Forging to Product and Process Development at Bethforge, Inc.~WILLIAM REESEn DAVID C RONEMUS KEYANG HUANG, EMORY W ZIMMERS JR., AND THIRU VEERABADRAN 224 A Rare Type of Flake-Like Forging Burst in Heavy Forgings~JOHN E STEINER 241 AND EDWARD L MURPHY A New Model for Calculating Maximum Blow Force of Die-Forging Hammer VUNRUI LI, KEYI YANG, AND ZHENLIN NI 249 T U R B I N E AND G E N E R A T O R F O R G I N G S Martensitic 11% CrMoNiNb Steel for Turbine Rotors in Geothermal Power StationS KARL H SCHONFELD, RALF LEVACHER, MICHAEL P MANNING AND PAUL F MURLEY Development of High-Strength 12 % Cr Ferritic Steel for Turbine Rotor Operating above 600~ TSUDA, MASAYUKI YAMADA RYUICHI 259 ISHII, YASUHIKO TANAKA, TSUKASA AZUMA, AND YASUMI IKEDA Historical Overview of Improving Cleanliness of Rotor Steels for Electric Utility ApplicationsmRAMASWAMYVlSWANATHAN 267 280 Prediction and Control of Segregations in CrMoV Steel Ingot for Monoblock I-ILP Rotor Forgings Using Experimental Results Obtained from Ton Sand Mold IngotS AKIHIRO ITOH,HITOmSAYAMADA,AND T O M O O TAKENOUCHI High Strength 12% Cr Heat Resisting Steel for High Temperature Steam Turbine Blade RYUICHI ISHII, YOICHI TSUDA, AND MASAYUKI YAMADA 305 317 Manufacturing and Properties of Newly Developed 9% CrMoVNiNbN HighPressure Low-Pressure Rotor Shaft ForgingmTSUKASA AZUMA, YASUHIKO TANAKA, TOHRU ISHIGURO, HAJIME YOSHIDA, AND YASUMI IKEDA 330 Hydrogen and Flaking after 40 Years of Vacuum Degassing JOHN E STEINER EDWARD L MURPHY, AND ROBERT D WILLIAMS 344 International Business, Codes, and Material Specifications MICHAEL GOLD 353 Indexes 363 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Overview Steel is supplied in many product forms, most of which are produced in terms of basic dimensions such as width and thickness, or diameter and with length describing quantity These products may be used by the foot for example as concrete reinforcing bar, or railroad rails or may be fabricated by bending, and welding into products such as storage tanks Often they essentially lose their identity in the process Forgings and castings by contrast are diverse in shape and form and are individually made for a specific purpose, either as self contained units such as crankshafts, valve bodies or turbine rotors, or as discrete components to be fabricated into a larger assembly, as for example a nozzle for a pressure vessel The specification and testing of forgings is therefore more varied, complex, and demanding than is the case for other product forms This is augmented by the fact that forgings are often expected to give better reliability and service performance than can be expected when the same part is fabricated from sections of other steel product forms, if this were in fact practical Given these unique circumstances the exchange of ideas on forging manufacturing techniques and experience, materials data and service experience has been an essential driving force in developing forging techniques and applications in every industrial field In turn these user driven needs and producer developments for manufacture have promoted the development of product specific standards that ASTM, by virtue of its organization capabilities and goals, is able to supply promptly and efficiently This then was the underlying purpose for both this symposium, and its predecessor held in Williamsburg Virginia in November 1984 The symposium was sponsored by ASTM Committee A01 on Steel, Stainless Steel, and Related Alloys, and was organized by Subcommittee A01.06 on Steel Forgings and Billets The symposium was international both in terms of the papers presented and the attendance The format of the symposium was similar to that of Williamsburg, focusing on the scope of the subcommittee in the areas of pressure vessel and nuclear forgings, turbine and generator forgings, general industrial forgings, and test methods for tbrgings Several of these authors who contributed to the first symposium also submitted papers for this the second symposium and so demonstrated an expansion of the developments in their organizations This was gratifying because time and financial restraints on travel have had a tendency to reduce the exchange of experience and data between those making steel forgings and those who use t h e m - - t o the detriment of both Although the maximum benefit will be gained by those who both attended the symposium and obtain this record of the proceedings, it is hoped that this publication extending as it does the published work of the Williamsburg conference will serve as a valuable reference volume for future forging applications The keynote address, developed by Mike Gold at very short notice but with keen insight into the current way in which business is being done in the international market, shows that the traditional way of manufacturing equipment in the established industrialized countries and exporting it to the underdeveloped nations is changing to the point that the equipment tends to be built in the destination country itself under a cooperative arrangement However there is still a niche where critical components, that may possibly include forgings, are made by the more experienced producers Although forgings for the domestic commercial nuclear applications are limited to the replacement of items such as steam generators for existing power generating stations, it will vii Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized viii STEEL FORGINGS be seen that the development of new manufacturing techniques, such as the forged stainless steel reactor piping units in France that will reduce in service inspection demands and improve component reliability, and the steam generator forging developments in Japan indicate that the nuclear technology continues to progress Developments intended to improve the mechanical properties of the ASTM A 508 Grade steel, used for many nuclear and other pressure vessel applications, have been described both from domestic and Korean producers, and these may result in revisions to that material grade in A 508, a potential example of specification development through technical exchange Developments in pressure vessel materials for forgings to be used in high pressure hydrogen environments in the petrochemical industry, and for the manufacture of spent nuclear fuel transportation casks also show how progress is being made in other sections of the pressure vessel industry The demand for very large and complex components for high temperature catalytic cracker vessels again for the petrochemical industry has spurred material development with consequent material specification revisions A potpourri of forging information was included in the General Industrial forging session This included process model development for the optimization of forging disks, and finite element modeling for open die forging Both of these papers were from domestic sources, and illustrate the drive to improve forging techniques A third paper on the forging process this time from China discussed forging hammer force calculation Sub harmonic treatment of forgings to relieve thermally induced residual stresses and the latest developments in the unique nitrogen alloyed stainless martensitic steels produced in Germany by the pressurized ESR melting process increased the diversity Other papers in this session also looked at current forging ingot production for the sole remaining domestic producer of very large open die forgings The manufacture of continuous grain flow crankshafts tbr medium speed diesel engines is described together with the required materials and properties The demand for this product has continued to increase, in part because of the use of natural gas for fuel and the potential for high thermal efficiencies when waste heat recovery is included in the installation Improved toughness grain refined high strength steels for forgings are described in the paper by Leap The information given is of a very practical nature and could prove to be useful in specifying heat treatments The often used sequence of normalizing, quenching, and tempering possibly owes its success to the mechanisms described in that paper One last area of interest here that could lead to specification revision also was the paper from England on the copper bearing age hardening steels for offshore tension leg platforms An area of forging problems all too rarely written about, but none-the-less real was discussed by two very experienced and long time members of the subcommittee This and their other paper on hydrogen flaking problems or the apparent lack of them in forgings gave rise to some spirited discussion which although it does not appear in this account, gave food tbr thought for those present, and deserves close attention to readers of this volume The germ of an idea for future papers on failure analysis in forgings came out of these discussions Always a source of information on the extremes of forging application the turbine and generator forgings session discussed developments in the martensitic stainless steels for turbine rotors and blades, as well as the combined high pressure low pressure rotor shafts in a modified 9CrlMo high temperature steel A study in the control of segregation in CrMoV steel ingots for the combined high pressure low pressure rotors was also presented, both papers coming from Japan The reader's attention is drawn to the excellent review of the superclean steel forging technology for rotor manufacture that has been spearheaded by EPRI This steel making practice, made possible by great strides in steel making technology was in its early days at the time of the Williamsburg meeting It is being Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized OVERVIEW ix extended to the high temperature pressure vessel field as a way to reduce in service embrittlement The steel forgings subcommittee has developed several widely used standards for specialized test methods for forgings, and this subject was covered by two papers on the ultrasonic examination of rotor forgings, one of which is included in this volume The advantages of being able to record ultrasonic examinations for base reference purposes will spur further activity in this area Although forging is an ancient production process long predating the industrial revolution, the development of steel forgings shows no sign of being exhausted, new forging machines continue to appear to make better use of the starting material and reduce cost, and new applications are put forward to meet the expanding needs of industry Symposia such as this one will assist in obtaining the best from our resources Edward G Nisbett National Forge Company, symposium co-chairman and STP editor Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Pressure Vessel and Nuclear Forgings Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproducti 354 STEELFORGINGS:.SECOND VOLUME engineer in a large boiler manufacturing company, and as an active participant in the development of ASME codes and ASTM materials specifications All of us at this symposium are interested in forgings, either as a manufacturer, or as a user, for their application in boilers, turbines, pressure vessels, and other large equipment For most of us, there have been dramatic, even catastrophic, changes since the first ASTM Forging Symposium in 1984 Then, our businesses were mostly domestic, and were largely nuclear oriented Now, our businesses are almost totally international, and, except for the replacement nuclear steam generators segment, largely fossil and petrochemical In brief, we have a global market, and, particularly from my perspective as a representative of a boiler manufacturer, it is on the other side of the world (whether we slice the globe EastWest or North-South) This is reflected in the increased participation in this symposium from representatives outside of North America IT'S A GLOBAL MARKET PLACE The domestic OEM boiler business has vanished, at least for the present, essentially because it is saturated Even the repair-replace-upgrade market has stagnated, due to the uncertainties of utility deregulation and consolidation The Babcock & Wilcox Power Generation Group still has major engineering and manufacturing facilities in North America, at: Melville, Saskatchewan; Cambridge, Ontario; Barberton, Ohio; West Point, Mississippi; and ParAs, Texas Babcock & Wilcox's corporate parent, McDermott, has their corporate headquarters here in New Orleans, Louisiana, where the symposium is being held On the other hand, Babcock & Wilcox has closed or sold significant manufacturing and engineering facilities in: Little Rock, Arkansas; Wilmington, North Carolina; Canton, Ohio; and Lynchburg, Virginia Instead, major joint venture facilities have been opened in Mexico, Egypt, Turkey, India, China, and Indonesia THE MARKET IS ON THE OTHER SIDE OF THE WORLD This shift has occurred for very fundamental reasons As a simple comparison of installed electric generating capacity versus population reveals, the new boiler market is largely in the Far East, Latin America, Middle East, and in Eastern Europe (Table 1) Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized GOLD ON INTERNATIONAL BUSINESS 355 TABLE I Comparative installed capacities Population (Millions) Canada 27 Installed Capacity (000 MW) Capacity per Person (Watts) 102 778 U.S.A 247 774 134 Western Europe 197 274 I 391 Japan 125 184 472 Russia 148 212 432 Latin America 453 160 353 153 50 327 Mexico 85 30 353 Argentina 34 16 471 Colombia 34 10 294 Peru 23 174 Venezuela 21 18 857 Chile 13 385 Asia-Pacific 902 413 142 China 170 175 150 India 900 80 89 Indonesia 195 18 92 Pakistan 120 12 96 Bangladesh 120 20 Vietnam 70 54 Thailand 60 13 208 Brazil The conclusion to be drawn from these data is that there will be essentially no new coal fired boiler construction in North America, Western Europe, or Japan This is reflected in Figure 1, which shows that 80% of the coal fired boilers to be installed in the period of 1994-2004 will occur in India, China, the Pacific Rim, and other locations (largely Eastern Europe and Latin America) The effect on Babcock & Wilcox is that in 1995, bookings where 81% international and only 19% in North America (Figure 2) This situation has been developing for some time, as seen in Figure 3, which identifies the location of Babcock & Wilcox OEM projects (boilers, replacement nuclear steam generators, and scrubbers) over the last ten years Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 356 STEELFORGINGS: SECONDVOLUME f China ~ 6% Korea I ~n d i ~ a RCifmiC4%Taiwan 4% Thailand Japanw.~6~~ 4% Indonesia Europe Other ' ~ ~ Philippines Total 240 GWe FIG Coal-Fired boilers to be installed between 1994 and 2004 ,A, ~ Canada FIG 1995 Babcock & Wilcox Power Generation Group bookings Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions aut GOLD ON INTERNATIONAL BUSINESS Chile China Egypt Indonesia israel T~Aan 25 2 ~j,~-~, ~ ~'- ~'~ ~ \ ~ ~'~_i"~ / J ~ ( ~ ~-'~ ~-~ ~j )~"~/~" ~? / R e p l a c e m e n t Nuclear /~ ~ Steam Generators United States , ~3,~-~ ~,,~0 /7 '~(~J p~'~/'~ - _~w ,o~ 357 ~'ee Scrubbers~ ~']'f ~ ~-~: ; ~176 E:g/and ~ ~ USA Korea 10 "~ % /~v ~ ~ FIG Babcock & Wilcox OEM projects, 1986 to 1995 JOINT VENTURES ARE REQUIRED Participation in joint venture companies in the customer's country is necessary, just to be considered a qualified vendor Joint ventures with foreign partners can have benefits of significant cost reductions, equity contributions, and influence with local customers Selecting the fight partner provides local market knowledge and an understanding of the philosophy of local business Contracts for the boilers at Suralaya and Tanjung Jati, in Indonesia, would not have been possible without the joint venture with PT Babcock & Wilcox, on Batam Island (Figure 4) Babcock & Wilcox's participation in the 25 boilers in China would not have been possible without the joint venture with the Babcock & Wilcox Beijing Company This plant, ten miles west of Tain'an men Square has hundred of acres of land, 200 000 sq ft (111 000 mz) of production buildings, 900 Chinese employees, and Babcock & Wilcox ex-patriot employees Participation in the Egyptian market (Figure 5) would not be possible without the joint venture, Babcock & Wilcox Egypt, in Cairo In some of these markets there is still a significant growth potential as shown by Figure Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 358 STEEL FORGINGS: SECOND VOLUME ~ DONESIA ~ Boiler Factory BatamIsland / \ Sura!aya A_,1 &~-~J.,,~k~-~ TanjungJati B Suralaya A, & ~ -~-.k/~-~ o Suralaya-~S~-~c~7 Q ~ FIG Babcock & Wilcox boiler projects in Indonesia Damanhoor Moussa FIG Babcock & Wilcox boiler projects in Egypt Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authoriz GOLD ON INTERNATIONALBUSINESS 359 FIG Installed capacities per person: saturated markets and growth markets The increased manufacturing and engineering capacity, represented in these joint venture companies, will eventually be brought to bear in other ventures, and in our domestic market when it recovers This will have a significant impact on Babcock & Wilcox's North America manufacturing and engineering resources But the alternative is not to be in this business at all ASME CODE ACCEPTED BUT NOT ALWAYS COMPETITIVE In these new international markets, the ASME Boiler Code is accepted, but not exclusively, as it is in the United States and Canada Other codes may be accepted equally, or may even be preferred Some countries permit design to the ASME Code, as long as local codes are also met (e.g India and the Czech Republic) Other internationally accepted codes are occasionally less conservative than the ASME Code, which can put North America companies, used to using the ASME code only, at some disadvantage This is illustrated in Figure 7, which shows the criteria used by the ASME Boiler and Pressure Vessel Committee, to establish the allowable stresses for the new grade 91 (9Cr-IMo-V) -alloyproduct forms, which have recently been introduced in boiler applications The allowable design stress at any given temperature is the lowest value of any of these curves Thus, the maximum allowable design stress for fossil boiler construction, for A336 F91, at 1000~ (540~ under the ASME Code is 14.3 ksi (98.6 MPa) This value is controlled by the tensile strength criterion in the ASME Code Some major European codes not use a tensile strength criterion and their allowable stress value, at 1000~ (540~ is controlled by the rupture criterion This leads to a value closer to 18 ksi (124 MPa), which is about 25% higher than the ASME value This difference leads to a significant difference in component thickness, weight, and cost The Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 360 STEEL FORGINGS: SECOND VOLUME conservatism of the European design is much less than that using the ASME Code This is counter balanced, to some extent, by tighter controls on materials manufacturers, amounting to virtual certification of materials manufacturers Even with these additional controls, the finished European component is considerably less expensive, and is perceived to be equally safe 40 (276) ~ v 30 , (207) i n _9 ,_ _, , ~e2o ( 138) 10 ,, 2/3 Yield I 100 200 (38) ~3) I = Creep I L I 1.1/4 T e n s i l e ~ ~ I I Ruture I 0.67 Ava & 0._80 Min I I I I 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 (1~) G~) ~ ) (316) (371) (427) (482) (538) (593) (649) (704) (760) Temperature, * F (*C) FIG A336-F91 allowable stress criteria WORLD SOURCING OF MATERIALS Even for components manufactured in Babcock & Wilcox's North American facilities, the major sources of pressure part raw materials supply (primarily tubing, pipe, plate, castings, and forgings) has shifted from almost totally domestic to largely international In order of tonnage, major countries of supply are Japan, the United States, France, and Germany Babcock & Wilcox's purchasing department anticipates that China will also become a major source, within a few years Likewise, for new boiler facilities in the world market, fabricated components will be manufactured in many of the joint ventures locations, for assembly at the plant site Figure shows that, for the current facilities being built at El Kureimat, in Egypt, major components are being supplied by B&W facilities in Canada, China, and India, as well as those in Egypt Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized GOLD ON INTERNATIONALBUSINESS 361 International Operations %%%~176176 FIG Sources of manufactured components for boilers at El Kureimat, Egypt L O C A L MATERIALS AN OPTION Some markets permit design and manufacture to the ASME Code, with a significant amount of local material content So far, this has meant that local materials have been used for non-pressure components But this situation will not last long Most nondomestic materials producers will readily make their products to ASME and ASTM materials specifications However, in some locations, it would be possible to use materials to JIS, DIN, or CEN specifications, and in a few cases these maybe preferred CHANGES TO CODES AND SPECIFICATIONS To facilitate use of materials made to non-domestic specifications, the ASME Boiler & Pressure Vessel Committee has removed the structural impediments to the use of materials made to intemationa! standards other than ASTM Steps have been initiated to incorporate two such materials, a structural steel made to Canadian Standards Association specification CSA G40.21-92, for a material similar to A36 but with better toughness at low temperatures; and a European Committee for Standardization (CEN) Specification, EN 10028-2:1992, for pressure vessel steel similar to A516 Further, ASME has taken steps to review factors of conservatism that appear to make the products designed to its codes less competitive in the world market For example, an active study is underway to Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 362 STEELFORGINGS: SECOND VOLUME consider reducing the criterion for tensile strength, from I + 4, to 1.1 - 3.5 In my view this is too small a step: I think ASME ought to consider eliminating the tensile strength criterion, as some European codes have done This will require other steps, to deal with stress concentrations, strain concentrations, and the increased use of high yield strengthto-tensile strength ratio materials that will result Elimination of the tensile strength criterion is still likely to lead to components that are much more competitive with those designed to European codes Similar avenues ought to be pursued by ASTM specification writing committees Some items that ought to be considered are: increased uniformity of requirements across product forms for the same alloy; tolerances that recognize those of the same product produced by manufacturers in other major industrialized countries (particularly those in Japan and Western Europe); and more freedom to use test methods permitted by other international codes My final message is that it is a small and rapidly changing world, and if we, in the major manufacturing industries, and on code and specification writing committees, not respond to the changes quickly, we will not survive the competition, much less have an opportunity to win it ACKNOWLEDGMENTS Much of the information in this paper was assembled from Babcock & Wilcox information, and was developed by P.E Ralston and L.M Shepard I am grateful for their permission to use it The opinions and suggestions concerning issues associated with the ASME Boiler and Pressure Vessel Code or ASTM material specifications are entirely my own and not necessary represent the views of ASME or ASTM Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized STP1259-EB/Jan 1997 Author Index Kim, K.-C., 18 Kirschner, W., 104 Kusuhashi, M., 56 Kwon, H.-K., 18 A Antos, D J., 129 Azuma, T., 267, 330 L B Leap, M J., 160 Levacher, R., 259 Li, Y., 249 Lin, M., 33 Lueg, J., 104 Bocquet, P., 3, 65 C Cheviet, A., 3, 65 Coudreuse, L., M 13 Malas, J C., 116 Manning, M P., 259 Morin, F., 65 Mozden, C A., 160 Murley, P F., 259 Murphy, E L., 241, 344 Dumont, R., F Fielding, J E., 93 Fischer, C E., 116 Focht, R B., 33, 93 N Nelson, T D., 33 Ni, Z., 249 Nisbett, E G., 129 G Gold, M., 353 Gunasekera, J S., 116 P H Price, S., 79, 196 Hansen, S S., 33 Hebel, T E., 148 Honeyman, G A., 79 Huang, K., 224 R Reese, W., II, 224 Reppert, K F., 93 Ronemus, D C., 224 Ikeda, Y., 267, 330 Ishii, R., 267, 317 Ishiguro, T., 330 Itoh, A., 305 Sato, I., 56 Sch6nfeld, K H., 259 Stein, G., 104 Steiner, J E., 241, 344 Suzuki, K., 56 K Kim, J.-M., 18 Kim, J.-T., 18 363 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Copyright9 by ASTM International Downloaded/printed by www.aslm.org University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 364 STEEL FORGINGS: SECOND VOLUME T Takenouchi, T., 305 Tanaka, Y., 267, 330 Tihansky, E L., 93 Tsuda, Y., 267, 317 Tsukada, H., 56 V Veerabadran, T., 224 Viertl, J R M., 213 Viswanathan, R., 280 W Walsh, M A., 196 Williams, R D., 344 Wingert, J C., 160 Y Yamada, H., 305 Yamada, M., 267, 317 Yang, K., 249 Yoshida, H., 330 Z Zimmers, E W., Jr., 224 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized STP1259-EB/Jan 1997 Subject Index A D Aerospace industry, 104 Aging, 196, 33O resistance, 65 Aluminum, 18, 56, 79 American Society of Mechanical Engineers code, 3, 353 Anvil block, 249 ASTM standards, 353 A 707, 196 Austenite grain size, 160 Austenitizing, 33 Aviation industry, 104 B Bearing journal wear, 129 Blow force, maximum, 249 Bottom pouring, 93 Bursts, forging, 241 Deformation, 249 Density difference, 305 Deoxidation, 18, 56 Detection and characterization, 213 Die-forging hammer, 249 Disk forginigs, 280 Disk manutacturmg, process model development, 116 E Electric Power Research Institute, 280 Electric utility applications, 280 Embrittlement, 3, 280 F C Carbon, 79, 104, 196 carbon monoxide reaction, 56 Chromium, 33, 330 Chromium ferritic steel, 267, 317 Chromium-manganese-nickel alloy, 79 Chromium-molybdenum-nickelniobium steel, 259 Chromium-molybdenum vanadium steel, 3, 241, 305 Copper precipitates, 196 Corrosion resistance, 104, 259 Corrosion, stress, 280 Cracking, premature, 148 Crack propagation, unstable, 160 Crankshafts, grain flow, 129 Creep, 3, 280 rupture strength, 267, 317 CRONIDUR, 104 Fatigue crankshaft, 129 life, 148 low cycle, 330 FEM modeling, 224 Ferrite, 65 Ferritic steel, 267, 317 Finite element method, 224 Flake-like defect, 241 Flaking, 241, 344 Flasks, transport, 79 Fracture, 241 brittle, 160 ductile, 160 toughness, 330 toughness, plane strain, 18 G Gear component forging, 241 Generators, 129 rotors, 213 Geothermal power station, 259 Grain flow crankshaft, 129 365 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 366 STEEL FORGINGS: SECOND VOLUME Grain refining, 56 precipitates, 160 Grain size, 79 austenite, 18 H Hammer, die-forging, 249 Hardness, aviation stainless steels, 104 Head-forming, 224 Hydrogen, 344 Hydrogen damage, Hydrogen flakes, 241 Impact toughness, 160 Inclusions, effect on toughness, 305 Indication sets, 213 Induction hardening, 129 Ingot cogging, 224 Ingot production, 93 International business, 353 Joint ventures, 353 L Ladle refining, 93, 344 Laves phase, 317 Lead hner, 79 Locomotive engine crankshafts, 129 Molybdenum, carbides, 33 effect on creep rupture strength, 267, 317 effect on segregation, 305 in martensitic stainless steels, 104, 259 in pressure vessel steels, 3, 18 in steel forging bursts, 241 in superclean steels, 330 N Nickel, 305, 330 in pressure vessel steel, 18, 33 in steel forging bursts, 241, 259 in transport casks, 79 Nickel chromium molybdenum vanadium, 241 Nil-ductile transition temperature, 18, 33 Niobium, 104, 259, 305, 317, 330 Nitriding, 129 Nitrogen, 104, 330 Nitrogen-alloyed stainless steels, 104 Nozzle integration, 56 Nuclear power plant forgings pipings, 65 pressure vessels, 18, 33, 93 steam generators, 56 transport casks, 79 O Open die forging process, 224 Optimization, forged disk manufacturing processes, 116 M Machining, 116 distortion following, 148 Manganese, 18, 79, 305, 330 Martensite, 160 Mechanical stress relief, 148 Models and modeling computer assisted design, 224 development, simplified forging, 116 FEM, 224 methodologies, 224 prediction, 305 P Piping, primary, 65 Power generation diesel engine crankshafts, 129 Precipitates, copper, 196 Pressure vessels nuclear, 18, 33, 93 oil industry, Pressurized slag remelting, 104 Process model development, 116 Punch forming, 224 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized INDEX 367 R Rhenium, 317 Rollsl 93 Rotors, 93, 213, 259, 267, 344 superclean steels, 280, 305 S Segregation prediction, 305 Sih'con, 33, 56 Silicon killing, 18 Steam drumhead integration, 56 Steel and steel alloys A 508, Class 3, 18 A 508, Grade 1, 33 AISI 304L, 65 carbon-manganese-nickel alloy, 79 chromium fern'tic, 267, 317 chromium-molybdenum (vanadium), 3, 241, 305 copper-bearing, 196 ferritic, 267 forged, 79, 344 high strength, 160 low alloy, 196, 213 manufacturing, 93 SA508, Class 3, 56 stainless, austenitic, 65 stainless, martensitic, 104, 160, 241, 259 superclean, 280, 305, 330 Stress corrosion, 280 Stress relief, 148 Structure property relationships, 196 Sulfur flaking, 344 T Tensile strength, 259 Tension leg platform, 196 Thermal efficiencies, 267 Thermal flakes,.241 Transport flasks, spent nuclear fuel, 79 Tungsten, 317 Turbine disks or blades, 104, 317 Turbine rotors, 213, 259, 267, 280 Turbine, steam, 317, 330 U Ultrasonic testing, 65, 241 rotor, 213 Upper-nose temper embrittlement, 33 V Vacuum carbon deoxidation, 18, 56 Vacuum degassing, 344 Vacuum stream degassing, 93 Vanadium, 3, 104, 241, 305, 330 Vibration stress relief, 148 W Welding, 148 Welds, 65 distortion and cracking, 148 Worldwide business, 353 Y Yield strength, 259 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:29:15 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized ISBN 0-8031-2423-6