HIGH-TEMPERATURE LOW-CYCLE FATIGUE BEHAVIOR AND CRACK INITIATION LIFE PREDICTION OF P91 STEEL BASED ON CRYSTAL PLASTICITY THEORY

Li Tengfei; Li Dongming; Chen Ziguang; Yu Wenshan; Kan Qianhua; Zhang Xu

doi:10.6052/0459-1879-25-009

Volume 57 Issue 5

May 2025

Turn off MathJax

Article Contents

Abstract

References

Chinese Journal of Theoretical and Applied Mechanics > 2025 > 57(5): 1160-1173. > DOI: 10.6052/0459-1879-25-009 CSTR: 32045.14.0459-1879-25-009

Li Tengfei, Li Dongming, Chen Ziguang, Yu Wenshan, Kan Qianhua, Zhang Xu. High-temperature low-cycle fatigue behavior and crack initiation life prediction of P91 steel based on crystal plasticity theory. Chinese Journal of Theoretical and Applied Mechanics, 2025, 57(5): 1160-1173. DOI: 10.6052/0459-1879-25-009

Citation:

PDF (3582 KB)

HIGH-TEMPERATURE LOW-CYCLE FATIGUE BEHAVIOR AND CRACK INITIATION LIFE PREDICTION OF P91 STEEL BASED ON CRYSTAL PLASTICITY THEORY

*.
Advanced Structural Material Mechanics and Service Safety Key Laboratory of Sichuan Province, School of Mechanics and Aerospace Engineering, Southwest Jiaotong University, Chengdu 611756, China
†.
Dongfang (Guangzhou) Heavy Machinery Co., Ltd., Guangzhou 511455 , China
**.
Department of Engineering Mechanics, School of Aerospace Engineering, Huazhong University of Science and Technology, Wuhan 430074 , China
††.
State Key Laboratory for Strength and Vibration of Mechanical Structures, School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an 710049, China

Received Date: January 06, 2025
Accepted Date: March 20, 2025
Available Online: March 21, 2025
Published Date: March 24, 2025

Graphical Abstract

Abstract

Abstract

P91 steel is widely utilized in critical structural components due to its outstanding performance in high-temperature environments. However, its cyclic softening behavior and the initiation mechanisms of fatigue cracks are not yet fully understood, which hinders the reliability design and lifespan prediction of the material. In this context, the present study proposes a crystal plasticity-based constitutive model grounded in physical mechanisms. The model systematically accounts for the evolution of back stress, martensitic lath coarsening, and dislocation glide/climb mechanisms, and is implemented using the finite element method. The simulation results effectively replicate the experimental observations of P91 steel under high-temperature cycling, thereby validating the accuracy and applicability of the model. The findings indicate that the cyclic softening behavior of P91 steel at elevated temperatures is primarily driven by microstructural recovery processes, including martensitic lath coarsening and a reduction in dislocation density. Fatigue cracks are observed to preferentially initiate at grain boundaries or triple-junctions. The crack initiation life is predicted using two fatigue indicator parameters (FIPs): accumulated plastic slip and accumulated energy dissipation. The results demonstrate that both FIPs exhibit strong predictive capability, with all predicted data points falling within the two-fold error band. Under high strain amplitude conditions, the fatigue life prediction based on accumulated energy dissipation provides higher accuracy, underscoring its potential for application in high-temperature fatigue behavior research. This study provides a comprehensive scientific foundation for understanding the cyclic plasticity behavior and fatigue crack initiation mechanisms in P91 steel, and offers a robust methodological framework for the reliability design of high-temperature materials.
- P91 steel,
- crystal plasticity theory,
- cyclic softening,
- martensitic lath coarsening,
- life prediction

FullText(HTML)

References (57)

References

[1]	Li M, Barrett RA, Scully S, et al. Cyclic plasticity of welded P91 material for simple and complex power plant connections. International Journal of Fatigue, 2016, 87: 391-404 doi: 10.1016/j.ijfatigue.2016.02.005
[2]	Farragher TP. Thermomechanical analysis of P91 power plant component. 2014
[3]	Song K, Wang K, Zhao L, et al. A physically-based constitutive model for a novel heat resistant martensitic steel under different cyclic loading modes: Microstructural strengthening mechanisms. International Journal of Plasticity, 2023, 165: 103611 doi: 10.1016/j.ijplas.2023.103611
[4]	Nguyen TT, Yoon KB, Park J, et al. Characterization of strain-controlled low-cycle fatigue and fracture behavior of P91 steel at elevated temperatures. Engineering Failure Analysis, 2022, 133: 105887 doi: 10.1016/j.engfailanal.2021.105887
[5]	Sauzay M, Fournier B, Mottot M, et al. Cyclic softening of martensitic steels at high temperature—Experiments and physically based modelling. Materials Science and Engineering: A, 2008, 483-484: 410-414 doi: 10.1016/j.msea.2006.12.183
[6]	Sauzay M, Brillet H, Monnet I, et al. Cyclically induced softening due to low-angle boundary annihilation in a martensitic steel. Materials Science and Engineering: A, 2005, 400: 241-244
[7]	Fournier B, Sauzay M, Caës C, et al. Analysis of the hysteresis loops of a martensitic steel. Part I: Study of the influence of strain amplitude and temperature under pure fatigue loadings using an enhanced stress partitioning method. Materials Science and Engineering: A, 2006, 437(2): 183-196 doi: 10.1016/j.msea.2006.08.086
[8]	Golański G, Mroziński S. Low cycle fatigue and cyclic softening behaviour of martensitic cast steel. Engineering Failure Analysis, 2013, 35: 692-702 doi: 10.1016/j.engfailanal.2013.06.019
[9]	Hu X, Huang L, Wang W, et al. Low cycle fatigue properties of CLAM steel at room temperature. Fusion Engineering and Design, 2013, 88(11): 3050-3059 doi: 10.1016/j.fusengdes.2013.08.001
[10]	Zecevic M, Knezevic M. A dislocation density based elasto-plastic self-consistent model for the prediction of cyclic deformation: Application to AA6022-T4. International Journal of Plasticity, 2015, 72: 200-217 doi: 10.1016/j.ijplas.2015.05.018
[11]	Chaboche JL. A review of some plasticity and viscoplasticity constitutive theories. International Journal of Plasticity, 2008, 24(10): 1642-1693 doi: 10.1016/j.ijplas.2008.03.009
[12]	孙莉, 郭素娟, 苑光健等. 宏/微观循环本构模型及其在工程结构中的应用. 机械工程学报, 2021, 57(16): 198-217 (Sun Li, Guo Sujuan, Yuan Guangjian, et al. Macro/micro cyclic constitutive models and their application in engineering structures. Journal of Mechanical Engineering, 2021, 57(16): 198-217 (in Chinese) doi: 10.3901/JME.2021.16.198 Sun Li, Guo Sujuan, Yuan Guangjian, et al. Macro/micro cyclic constitutive models and their application in engineering structures. Journal of Mechanical Engineering, 2021, 57(16): 198-217 (in Chinese) doi: 10.3901/JME.2021.16.198
[13]	罗诚, 袁荒. 基于张量化微结构表征的筏化镍基单晶高温合金疲劳寿命评估. 力学学报, 2024, 56(7): 2029-2050 (Luo Cheng, Yuan Huang. Fatigue life evaluation of rafted nickel-base single crystal superalloys based on tensorial microstructure characterization. Chinese Journal of Theoretical and Applied Mechanics, 2024, 56(7): 2029-2050 (in Chinese) Luo Cheng, Yuan Huang. Fatigue life evaluation of rafted nickel-base single crystal superalloys based on tensorial microstructure characterization. Chinese Journal of Theoretical and Applied Mechanics, 2024, 56(7): 2029-2050 (in Chinese)
[14]	Sangid MD. The physics of fatigue crack initiation. International Journal of Fatigue, 2013, 57: 58-72
[15]	熊骏, 李振环, 朱亚新等. 基于微结构动态演化机制的单晶镍基高温合金晶体塑性本构及其有限元模拟. 力学学报, 2017, 49(4): 763-781 (Xiong Jun, Li Zhenhuan, Zhu Yaxin, et al. Microstructure evolution mechanism based crystal-plasticity constitutive model for nickel-based superalloy and its finite element simulation. Chinese Journal of Theoretical and Applied Mechanics, 2017, 49: 765-781 (in Chinese) Xiong Jun, Li Zhenhuan, Zhu Yaxin, et al. Microstructure evolution mechanism based crystal-plasticity constitutive model for nickel-based superalloy and its finite element simulation. Chinese Journal of Theoretical and Applied Mechanics, 2017, 49: 765-781 (in Chinese)
[16]	Roters F, Eisenlohr P, Hantcherli L, et al. Overview of constitutive laws, kinematics, homogenization and multiscale methods in crystal plasticity finite-element modeling: Theory, experiments, applications. Acta Materialia, 2010, 58(4): 1152-1211
[17]	Li DF, Golden BJ, O’Dowd NP. Multiscale modelling of mechanical response in a martensitic steel: A micromechanical and length-scale-dependent framework for precipitate hardening. Acta Materialia, 2014, 80: 445-456
[18]	Yu L, Liu W, Sui H, et al. A dislocation-based model for cyclic plastic response of lath martensitic steels. Acta Mechanica Sinica, 2022, 38(2): 421353 doi: 10.1007/s10409-021-09079-4
[19]	Manonukul A, Dunne F. High- and low-cycle fatigue crack initiation using polycrystal plasticity. Proceedings of the Royal Society of London Series A: Mathematical, Physical and Engineering Sciences, 2004, 460(2047): 1881-1903
[20]	Han QN, Rui SS, Qiu W, et al. Crystal orientation effect on fretting fatigue induced geometrically necessary dislocation distribution in Ni-based single-crystal superalloys. Acta Materialia, 2019, 179: 129-141
[21]	Liu L, Wang J, Zeng T, et al. Crystal plasticity model to predict fatigue crack nucleation based on the phase transformation theory. Acta Mechanica Sinica, 2019, 35(5): 1033-1043
[22]	Yuan GJ, Zhang XC, Chen B, et al. Low-cycle fatigue life prediction of a polycrystalline nickel-base superalloy using crystal plasticity modelling approach. Journal of Materials Science & Technology, 2020, 38: 28-38
[23]	Li KS, Wang RZ, Yuan GJ, et al. A crystal plasticity-based approach for creep-fatigue life prediction and damage evaluation in a nickel-based superalloy. International Journal of Fatigue, 2021, 143: 106031
[24]	Hill R, Rice JR. Constitutive analysis of elastic-plastic crystals at arbitrary strain. Journal of the Mechanics and Physics of Solids, 1972, 20(6): 401-413 doi: 10.1016/0022-5096(72)90017-8
[25]	Song S, Kan Q, Liu Y, et al. Tensile and creep behavior of 316L austenite stainless steel at elevated temperatures: Experiment and crystal plasticity modeling. Acta Mechanica Sinica, 2023, 40(2): 423091
[26]	Kords C, Raabe D. On the Role of Dislocation Transport in the Constitutive Description of Crystal Plasticity. epubli GmbH, 2013
[27]	Frederick CO, Armstrong PJ. A mathematical representation of the multiaxial Bauschinger effect. Materials at High Temperatures, 2007, 24(1): 1-26 doi: 10.3184/096034007X207589
[28]	Fischer T, Zhou T, Dahlberg CFO, et al. Relating stress/strain heterogeneity to lath martensite strength by experiments and dislocation density-based crystal plasticity. International Journal of Plasticity, 2024, 174: 103917 doi: 10.1016/j.ijplas.2024.103917
[29]	Gui Y, An D, Han F, et al. Multiple-mechanism and microstructure-based crystal plasticity modeling for cyclic shear deformation of TRIP steel. International Journal of Mechanical Sciences, 2022, 222: 107269 doi: 10.1016/j.ijmecsci.2022.107269
[30]	Taylor GI. The mechanism of plastic deformation of crystals. Part I. Theoretical. Proceedings of the Royal Society of London Series A, Containing Papers of a Mathematical and Physical Character, 1934, 145(855): 362-387
[31]	Jin X, Zhu B, Li Y, et al. Effect of the microstructure evolution on the high-temperature strength of P92 heat-resistant steel for different service times. International Journal of Pressure Vessels and Piping, 2020, 186: 104131 doi: 10.1016/j.ijpvp.2020.104131
[32]	Abe F. Precipitate design for creep strengthening of 9% Cr tempered martensitic steel for ultra-supercritical power plants. Science and Technology of Advanced Materials, 2008, 9(1): 013002 doi: 10.1088/1468-6996/9/1/013002
[33]	Barrett RA, O’Donoghue PE, Leen SB. A dislocation-based model for high temperature cyclic viscoplasticity of 9-12Cr steels. Computational Materials Science, 2014, 92: 286-297 doi: 10.1016/j.commatsci.2014.05.034
[34]	Blum W, Eisenlohr P. Dislocation mechanics of creep. Materials Science and Engineering: A, 2009, 510-511: 7-13 doi: 10.1016/j.msea.2008.04.110
[35]	Ma A, Roters F. A constitutive model for fcc single crystals based on dislocation densities and its application to uniaxial compression of aluminium single crystals. Acta Materialia, 2004, 52(12): 3603-3612 doi: 10.1016/j.actamat.2004.04.012
[36]	Argon AS, Moffatt WC. Climb of extended edge dislocations. Acta Metallurgica, 1981, 29(2): 293-299 doi: 10.1016/0001-6160(81)90156-5
[37]	易敏, 胡文轩. 晶体塑性模型及其在金属疲劳寿命预测中的应用. 南京航空航天大学学报, 2023, 55(1): 12-27 (Yi Min, Hu Wenxuan. Crystal plasticity model and its application for fatigue life prediction of metals. Journal of Nanjing University of Aeronautics & Astronautics, 2023, 55(1): 12-27 (in Chinese) Yi Min, Hu Wenxuan. Crystal plasticity model and its application for fatigue life prediction of metals. Journal of Nanjing University of Aeronautics & Astronautics, 2023, 55(1): 12-27 (in Chinese)
[38]	郑战光, 覃里杜, 谢昌吉等. 晶体塑性疲劳指示因子研究方法综述. 机械工程学报, 2022, 58(8): 105-116 (Zheng Zhanguang, Qin Lidu, Xie Changji, et al. Research progress of crystal plastic fatigue indicator parameters. Journal of Mechanical Engineering, 2022, 58(8): 105-116 (in Chinese) Zheng Zhanguang, Qin Lidu, Xie Changji, et al. Research progress of crystal plastic fatigue indicator parameters. Journal of Mechanical Engineering, 2022, 58(8): 105-116 (in Chinese)
[39]	Cruzado A, Lucarini S, LLorca J, et al. Crystal plasticity simulation of the effect of grain size on the fatigue behavior of polycrystalline Inconel 718. International Journal of Fatigue, 2018, 113: 236-245 doi: 10.1016/j.ijfatigue.2018.04.018
[40]	Roters F, Diehl M, Shanthraj P, et al. DAMASK—The Düsseldorf Advanced Material Simulation Kit for modeling multi-physics crystal plasticity, thermal, and damage phenomena from the single crystal up to the component scale. Computational Materials Science, 2019, 158: 420-478 doi: 10.1016/j.commatsci.2018.04.030
[41]	Lu X, Zhao J, Wang Z, et al. Crystal plasticity finite element analysis of gradient nanostructured TWIP steel. International Journal of Plasticity, 2020, 130: 102703 doi: 10.1016/j.ijplas.2020.102703
[42]	Mirhosseini S, Perdahcıoğlu ES, Atzema EH, et al. Response of 2D and 3D crystal plasticity models subjected to plane strain condition. Mechanics Research Communications, 2023, 128: 104047 doi: 10.1016/j.mechrescom.2023.104047
[43]	Diehl M, An D, Shanthraj P, et al. Crystal plasticity study on stress and strain partitioning in a measured 3D dual phase steel microstructure. Physical Mesomechanics, 2017, 20(3): 311-323 doi: 10.1134/S1029959917030079
[44]	Ramazani A, Mukherjee K, Quade H, et al. Correlation between 2D and 3D flow curve modelling of DP steels using a microstructure-based RVE approach. Materials Science and Engineering: A, 2013, 560: 129-139 doi: 10.1016/j.msea.2012.09.046
[45]	Qayyum F, Chaudhry AA, Guk S, et al. Effect of 3D representative volume element (rve) thickness on stress and strain partitioning in crystal plasticity simulations of multi-phase materials. Crystals, 2020, 10(10): 944 doi: 10.3390/cryst10100944
[46]	Li DF, Barrett RA, O’Donoghue PE, et al. Micromechanical finite element modelling of thermo-mechanical fatigue for P91 steels. International Journal of Fatigue, 2016, 87: 192-202 doi: 10.1016/j.ijfatigue.2015.11.025
[47]	Fournier B, Sauzay M, Pineau A. Micromechanical model of the high temperature cyclic behavior of 9-12%Cr martensitic steels. International Journal of Plasticity, 2011, 27(11): 1803-1816 doi: 10.1016/j.ijplas.2011.05.007
[48]	Hollner S, Fournier B, Le Pendu J, et al. High-temperature mechanical properties improvement on modified 9Cr-1Mo martensitic steel through thermomechanical treatments. Journal of Nuclear Materials, 2010, 405(2): 101-108
[49]	Basirat M, Shrestha T, Potirniche GP, et al. A study of the creep behavior of modified 9Cr-1Mo steel using continuum-damage modeling. International Journal of Plasticity, 2012, 37: 95-107
[50]	Kumar MA, Capolungo L. Microstructure-sensitive modeling of high temperature creep in grade-91 alloy. International Journal of Plasticity, 2022, 158: 103411 doi: 10.1016/j.ijplas.2022.103411
[51]	Madec R, Kubin LP. Dislocation strengthening in FCC metals and in BCC metals at high temperatures. Acta Materialia, 2017, 126: 166-173
[52]	Golden BJ, Li DF, Tiernan P, et al. Deformation characteristics of a high chromium, power plant steel at elevated temperatures//Proceedings of the Pressure Vessels and Piping Conference, 2015. American Society of Mechanical Engineers
[53]	Wong SL, Madivala M, Prahl U, et al. A crystal plasticity model for twinning- and transformation-induced plasticity. Acta Materialia, 2016, 118: 140-151
[54]	Barrett RA, O'Donoghue PE, Leen SB. A physically-based constitutive model for high temperature microstructural degradation under cyclic deformation. International Journal of Fatigue, 2017, 100: 388-406
[55]	Li DF, Barrett RA, O'Donoghue PE, et al. A multi-scale crystal plasticity model for cyclic plasticity and low-cycle fatigue in a precipitate-strengthened steel at elevated temperature. Journal of the Mechanics and Physics of Solids, 2017, 101: 44-62
[56]	Hyde CJ, Sun W, Hyde TH, et al. Thermo-mechanical fatigue testing and simulation using a viscoplasticity model for a P91 steel. Computational Materials Science, 2012, 56: 29-33
[57]	Guguloth K, Sivaprasad S, Chakrabarti D, et al. Low-cyclic fatigue behavior of modified 9Cr-1Mo steel at elevated temperature. Materials Science and Engineering: A, 2014, 604: 196-206

[1]	Li Wenqi, Xiang Zhong, Li Haoran, Ren Zhongkai, Wang Jiadong. STUDY ON THE PREDICTION MODEL OF THE INTRINSIC DAMAGE DISSIPATION LIFE OF TWO-STAGE VARIABLE AMPLITUDE STRAIN FATIGUE[J]. Chinese Journal of Theoretical and Applied Mechanics, 2024, 56(1): 149-156. DOI: 10.6052/0459-1879-23-314
[2]	Qin Tianyu, Ren Xinyan, Hu Feifei, Liu Yujie, Ao Ni, Kan Qianhua, Wu Shengchuan, Kang Guozheng. REMAINING LIFE ASSESSMENT OF HOOK TAIL FRAME IN RAILWAY HEAVY-HAUL WAGON BASED ON REAL LOADING SPECTRUM[J]. Chinese Journal of Theoretical and Applied Mechanics, 2022, 54(7): 1830-1838. DOI: 10.6052/0459-1879-21-687
[3]	Liu Yuqing, Chen Zaigang, Ge Xin, Wang Kaiyun. SERVICE LIFE EVALUATION OF TRACTION MOTOR BEARINGS IN COMPLICATED VIBRATION ENVIRONMENT OF A LOCOMOTIVE[J]. Chinese Journal of Theoretical and Applied Mechanics, 2022, 54(7): 1820-1829. DOI: 10.6052/0459-1879-21-545
[4]	Li Jing, Tong Xiaolong, Yang Shuo, Qiu Yuanying. A MULTIAXIAL HIGH CYCLE FATIGUE LIFE PREDICTION MODEL CONSIDERING THE EFFECT OF MEAN STRESS FOR TENSION-TORSION LOADINGS WITH SAME FREQUENCY[J]. Chinese Journal of Theoretical and Applied Mechanics, 2020, 52(5): 1409-1421. DOI: 10.6052/0459-1879-20-066
[5]	Xiangyang Cui, Kecheng Hong. A MULTIAXIAL LOW-CYCLE FATIGUE MODEL CONSIDERING NON-PROPORTIONAL ADDITIONAL DAMAGE[J]. Chinese Journal of Theoretical and Applied Mechanics, 2019, 51(3): 863-872. DOI: 10.6052/0459-1879-18-347
[6]	Zhao Ernian, Qu Weilian. A NEW PROPOSAL FOR MULTIAXIAL LOW-CYCLE FATIGUE LIFE PREDICTION UNDER NON-PROPORTIONAL LOADING[J]. Chinese Journal of Theoretical and Applied Mechanics, 2016, 48(4): 944-952. DOI: 10.6052/0459-1879-15-377
[7]	Jiang Chao, Deng Qun, Li Bochuan. A NEW MULTIAXIAL FATIGUE LIFE PREDICTION MODEL BASED ON THE NONPROPORTIONAL ADDITIONAL DAMAGE[J]. Chinese Journal of Theoretical and Applied Mechanics, 2015, 47(4): 634-641. DOI: 10.6052/0459-1879-15-050
[8]	A new model for life prediction of multiaxial high-cycle fatigue[J]. Chinese Journal of Theoretical and Applied Mechanics, 2010, 42(6): 1225-1230. DOI: 10.6052/0459-1879-2010-6-lxxb2009-655
[9]	Weihong Zhang, Gaoming Dai, Fengwen Wang, Shiping Sun, Hicham Bassir. Topology optimization of material microstructures using strain energy-based prediction of effective elastic properties[J]. Chinese Journal of Theoretical and Applied Mechanics, 2007, 39(1): 77-89. DOI: 10.6052/0459-1879-2007-1-2006-086
[10]	Kejun Yang, Shuyou Cao, Xingnian Liu. Flow resistance in compound channels and its prediction methods[J]. Chinese Journal of Theoretical and Applied Mechanics, 2007, 39(1): 23-31. DOI: 10.6052/0459-1879-2007-1-2006-017

Cited By

Get Citation

PDF

XML

Article Metrics

Article views (161) PDF downloads (63)

HIGH-TEMPERATURE LOW-CYCLE FATIGUE BEHAVIOR AND CRACK INITIATION LIFE PREDICTION OF P91 STEEL BASED ON CRYSTAL PLASTICITY THEORY

Abstract

References

Related Articles

Catalog

Article Metrics

Related

Download Center

Author Center

HIGH-TEMPERATURE LOW-CYCLE FATIGUE BEHAVIOR AND CRACK INITIATION LIFE PREDICTION OF P91 STEEL BASED ON CRYSTAL PLASTICITY THEORY

Abstract

References

Related Articles

Catalog

Article Metrics

Related

Download Center

Author Center

Export File

Citation

Format

Content