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Copyright © Siemens AG 2009. All rights reserved.
Applications of Thermo-Calc and DICTRA
Thermo-Calc Users MeetingAachen, 2010-09-09
Sebastian PiegertE F PR GT EN M&T MPD3
Page 2 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Outline
Introduction
Siemens Gas Turbines
Applications of Thermo-Calc and DICTRA
Base Material CharacterisationBraze Alloy Development and Heat Treatment OptimisationHeat Treatment for a Welding Process
Summary
Page 3 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Introduction Structure of Siemens
Source: Siemens
Industry
Healthcare
Energy
Page 4 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Introduction Structure of Siemens Energy
Power Distribution
Power Transmission
Oil & Gas Fossil Power
Generation
Renewable
Energy
Energy Service
Products and Solutions for Energy −
in 6 Divisions
Page 5 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Introduction Overall Vision of Siemens Energy Sector
Page 6 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Siemens Gas Turbines Portfolio
SGT-100
SGT-200
SGT-300
SGT-400
SGT-500
SGT-600
SGT-700
SGT-800
SGT6-2000E
SGT5-2000E
SGT6-4000F
SGT6-5000F
SGT5-4000F
Industrial Gas TurbinesLarge Gas Turbines Values in MW @ ISO Conditions
292
200
187
168
113
47
30
25
17
13
8
7
5
375SGT5-8000H
SGT-400
SGT5-8000H
Page 7 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Siemens Gas Turbines SGT5-4000F (V94.3A) Gas Turbine
Compressor, 15 stage with CDA airfoils in all stages and with side-wall correction. One variable guide vane row. Developed with P&W.
Annular combustion chamber with 24 hybrid burners. Hot gas path with air cooled metallic or ceramic heat shield
4 -stage turbineBlade 1 and 2 single crystalline and directionally solidifiedFilm-cooling of blades and vanes of stage 1 and 2
Rotor with Hirth serration and single tie bolt. Quick thermal response because of rotor internal flow passages.
Excellent thermal balance due to:- Quick and stiff rotor- Conical turbine flow path
Due to thermal balance:- Quick start up- Hot restart capability
Combustion Chamber
Compressor
24 Hybrid Burners
Turbine
Page 8 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Siemens Gas Turbines Air Cooled Turbine Blades and Vanes
Bla
de
1 o
f SG
T5-4
00
0F
γ’
precipitation hardened Ni-based Superalloy
500
1000
1500
1940 1950 1960 1970 1980 1990 2000
Melting Interval1300
750
T Material= 85% Tm
Turbine Inlet Temperature
Co-BaseCarbide Hardening
Ni-Baseγ/γ‘
Ni-Base -
SXγ/γ‘
JahrTe
mp
erat
ur
°C
Page 9 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Applications of Thermo-Calc and DICTRA
Coating-SubstrateInteraction
Estimation ofnon Conformances
Heat Treatment Optimisation
Base MaterialCharacterisation
Braze AlloyDevelopment
Base AlloyDevelopment Thermo-Calc Version S
with TTNi
7 Database
DICTRA 25 with MobNi1 Database
Page 10 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
700
800
900
1000
1100
1200
1300
1400
0 1 2 3 4 5 6 7 8
T /
°C
minmaxTCC
Base Material Characterisation
–
IN 738 LC
Possible Calculations:solvus temperaturesamount of phases with respect to temperaturephase compositionsprediction of occurrence of detrimental phases such as s, h etc.
Applications:estimation of “allowed” service temperaturesdefinition of heat treatmentsinfluence of material non-conformances in regard to composition can be evaluated
Liq
Sol γ‘
M23
C6
MC
M3B
2 σ
Lite
ratu
revs
. Cal
cula
ted
T so
lvFr
acti
on
of
ph
ases
vsT
1: γ
2: MC
3: γ’
4: M23C6
5: M3B2
6: L
Tsol Tbraze
Page 11 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Development of a Boron Free Braze
Scope:Develop a boron free braze alloy to avoid formation of brittle phases.
Approach:use Ge as MPD
high solubility in Niforms a to γ’ isomorphous phase (β-Ni3Ge)
Problem:limited availability of phase diagramsGe not in database (TTNi7)
Bin
ary
Ni-
Ge
Phas
e D
iag
ram
Tbraze
Page 12 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Development of a Boron Free Braze Braze
Alloy Development
Issue:Ge braze BfBX-5 with X wt.-% MPD low melting eutectics, condensed γ’and TCP phases remain in jointpoor mechanical properties at 850 °C
Action:new alloy based on René 80Y wt.-% Ge are adequate for a liquidus lower than 1200 °Cdetrimental blocky phases and condensed γ’ were found within jointrefinement by means of TCC
Conclusion and Result:reduction of refractory metals Mo/Wreduction of γ’ formersmicrostructure is now homogeneousM
od
ifie
dB
raze
Allo
yR
ené
80
+ X
Y w
t.-%
Ge(
Si)
1: γ
2: Laves
3: L
4: γ’
5: NiAl
1: γ
2: Laves
3: L
4: γ’
5: NiAl
↓Al -
→Ti -
↓↓Mo -
↓W
Page 13 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Development of a Boron Free Braze Heat Treatment Development
Issue:appropriate braze cycle not available
Model:problem with moving interfacestart of calculation with L (braze) and γ (René 80)expected phases attached to lower interface, i.e. joint centre, as inactivew0 = 200 µm
Result:isothermal single phase solidification of old braze (BfBX-5) within 22 hsignificant reduction of tiso with René80 based brazeformation of Laves if Thold is significantly lowered
Req
uir
edTi
me
for
Solid
ific
atio
nTw
oC
ellM
od
el
1204 °C/24 h
1204 °C/30 min +1140 °C/24 h
15 h
7 h
René
80/BfBX-5 –
40/60
René
80 + Y Ge
Formationof Laves
Page 14 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
high temperature strength – γ’Ni3(Al,Ti)corrosion and oxidation resistant
BUT very prone to crackingin HAZ during welding (hot cracking)
solidification crackingcracking due to remeltinghot cracking due to loss in ductility
strain age crackingGenerally:
high γ’-content = higly prone to cracking
3 Gew.-% ≤ cAl + ½ cTiTa, Nb, Hf form also γ’
Weldability
of Superalloys
readly
weldable
Mo
le F
ract
ion
of γ‘
in t
ypic
al S
up
eral
loys
Page 15 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Increase
of Weldability
Low Low heatheat
inputinputBeamBeam
weldingwelding
(Laser, EB)(Laser, EB)
MicroMicro--PlasmaPlasma--PowderPowder--WeldingWelding
OptimisationOptimisation
of of weldingwelding
parametersparameters
HeatHeat
treatmenttreatment
WeldWeld--fillersfillersDuctileDuctile
weldweld--fillersfillers
(IN 625, IN 617, (IN 625, IN 617, HastelloyHastelloy
X)X)
PrePre--heatheat
treatmenttreatment
((solutioningsolutioning, ,
overageingoverageing) )
SubsequentSubsequent
heatheat
treatmenttreatment
HotboxHotbox--WeldingWelding
Page 16 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
DICTRA Heat Treatment for Micro Cladding
Fact:
γ‘
precipitation causes shrinkage and hence induces tensile stresses which can lead to cracking of weld deposition.
Question:
What heating rate is favourable to avoid strain age cracking?
Solution:
Result:low heating rate shall be appliedhigh heating rates led to a shift of precipitation to higher temperatures resulting in altered growth ratetotal volume fraction precipitated deviates by only 10 %
-5E-23
0
5E-23
1E-22
1.5E-22
2E-22
2.5E-22
3E-22
700 800 900 1000
T / °C
V /
m3 /s
20 K/min
10 K/min
5 K/min
γ’
γ
rγ’(T,t)
641 nm
movinginterface
Prec
ipit
atio
n R
ate
vs. T
Mo
del
Geo
met
ry
minK20
minK5
min≤≤T
V&
&
.
Page 17 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
Summary
Major Advantages:speed up of investigations and decrease time to marketreduction of experimental testing“long term trials” within hours/daysdefinition of process windows even of unknown systems possiblecalculation of stable and metastable„real“ systemsversatile: any type of calculation which is related to thermodynamics and/or kinetics can be thought ofinfluence of distinct parameters on the system can be studied separately
Disadvantages:non-validated material systems might give inappropriate resultssome knowledge about the systems is requiredmechanical properties cannot be predicted
Page 18 2010-09-09 Sebastian PiegertCopyright © Siemens AG 2009. All rights reserved.
Siemens Energy Sector F PR GT EN M&T MPD3
This document contains forward-looking statements and information –
that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will”
or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens’
control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained
in Siemens’
filings with the SEC, which are available on the Siemens website, www.siemens.com
and on the SEC’s
website, www.sec.gov. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected,
intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated.
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