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CHAPTER 5
CHAPTER 5
Dr. Talaat El- Benawy
CREEP TEST
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Several metallic components, which are used in heat
exchangers or boilers, are subjected to static
external loading under high temperature service
conditions which lead to a continuous deformation
with time.
Introduction
This phenomenon is so-called
creep
creep.
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In many designs these creep deformations must be maintained small must be maintained small
for the sake of avoiding failure or because of the principle of for the sake of avoiding failure or because of the principle of the the
manufacturing design manufacturing design. .
Importance of Creep
Importance of Creep
Excessive creep deformations may also lead to Excessive creep deformations may also lead to premature buckling premature buckling of of
structural members subjected to compressive loads. structural members subjected to compressive loads. Permanent Permanent
creep creep deformations under repetitive flight conditions are additive an deformations under repetitive flight conditions are additive and d
may reach such large values as to make an aircraft aerodynamical may reach such large values as to make an aircraft aerodynamical ly ly
unsatisfactory unsatisfactory.
For instance, if the creep deformations are not limited to small values, if the creep deformations are not limited to small values,
necessary clearances between moving and stationary parts, as in necessary clearances between moving and stationary parts, as in
steam and gas turbines, are not maintained. steam and gas turbines, are not maintained.
Furthermore, for certain stress values, the creep deformations m Furthermore, for certain stress values, the creep deformations may ay
become so large that fracture is produced during the lifetime of become so large that fracture is produced during the lifetime of the the
part part . .
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Creep Definition
Metals Handbook defined the creep as the slow
Metals Handbook defined the creep as the slow
deformation of a
deformation of a
material under a
material under a
stress that results in a
stress that results in a
permanent change in shape
permanent change in shape
.
.
In other words, creep can be defined as the plastic
In other words, creep can be defined as the plastic
deformation time
deformation time
-
-
dependent strain of a
dependent strain of a
material that is
material that is
subjected to a stress below its yield stress for a
subjected to a stress below its yield stress for a
prolonged period of time.
prolonged period of time.
Creep occurs for stresses below the yield point only when
the temperature
is exceeding about 0.3
is exceeding about 0.3
-
-
0.4 of the melting
0.4 of the melting
point of the material.
point of the material.
However, some nonferrous alloys
However, some nonferrous alloys
and metals such as lead and tin and their alloys exhibit
and metals such as lead and tin and their alloys exhibit
creep at low stresses and also at room temperatures.
creep at low stresses and also at room temperatures.
For
For
a number of nonmetallic materials, including various
a number of nonmetallic materials, including various
types of plastics, concrete, and wood, creep may also be
types of plastics, concrete, and wood, creep may also be
produced at low stresses and room
produced at low stresses and room
temperatures.
temperatures.
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Creep Testing Experiment Apparatus
Creep Testing Experiment Apparatus
Creep testing machine is consisting of three main pieces: Creep testing machine is consisting of three main pieces:
(1) (1) an electric furnace with suitable temperature controlling device an electric furnace with suitable temperature controlling device; ;
(2) an extensometer to measure the creep deformation and (2) an extensometer to measure the creep deformation and
(3) a loading setup system. (3) a loading setup system.
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Creep Data and Their Interpretation
Creep Data and Their Interpretation
Creep behavior of a material is determined by uniaxial loading of test
specimen under constant stress ( (o o) ) heated at temperature (T). (T). The obtained
result data from such experiment is a creep ( creep (c c) )- -time (t) time (t) curve as shown:
Elastic strain OA OA will occur upon
application of the load. At
elevated temperature strain OC OC
occurs upon the application of
the same stress o o. Strain under Strain under
this condition will be represented this condition will be represented
by the curve by the curve

OAB OAB. Strain OC OC
may be entirely elastic, or elastic elastic, or elastic
plus plastic, depending upon the plus plastic, depending upon the
material, temp. and stress. material, temp. and stress.

Strain increases as time of load
application extends as illustrated
by curve CDEF CDEF. This continued
increase in c c

with time, under
constant stress, is defined as
creep.
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In this stage the rate of strain hardening by dislocations is ba In this stage the rate of strain hardening by dislocations is balanced lanced
by the rate of recovery. by the rate of recovery.
In initial stage initial stage the total
deformation is elastic due
to application of the load.
In first stage (Primary first stage (Primary
Creep), Creep), creep continues at
a decreasing rate as the
strain hardening is the
dominating factor on the
creep deformation.
In second stage second stage, creep
rate becomes constant
and this stage is thereby
called steady state region steady state region.
Creep sequence mainly
consists of three stages three stages as
well as the initial stage initial stage.
In third (final) stage third (final) stage, a rapid increase in creep rate can be observed,
which continues until fracture occurs.
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In In third stage third stage, high strains , high strains
produced will start to cause produced will start to cause
necking in specimen, which will necking in specimen, which will
cause cause increase in the local stress increase in the local stress
and eventually the material will and eventually the material will
pull apart in a pull apart in a ductile fracture ductile fracture
around the defects which could around the defects which could
be pre be pre- -existed in the material. existed in the material.
These defects could be These defects could be
precipitates at high temperatures precipitates at high temperatures
or grain boundaries. or grain boundaries.
In fact, this region is not important to normal operation and cr In fact, this region is not important to normal operation and creep eep
design criteria since it is usually to end the serviceable life design criteria since it is usually to end the serviceable life of any of any
component at the end of the steady state creep region component at the end of the steady state creep region (second (second
stage) stage). .
It has to be mentioned that for the lower stresses and It has to be mentioned that for the lower stresses and
temperatures, the final stage of creep is not observable during temperatures, the final stage of creep is not observable during
the usual times covered by creep tests. the usual times covered by creep tests.
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Given figure shows the effect of stress and temperature on the Given figure shows the effect of stress and temperature on the
creep creep- -time curve. time curve. o o

1 1

> >o o
2 2
> >s s
3 3
and T and T
1 1
>T >T
2 2
>T >T
3 3
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Creep Testing Machine
Creep Testing Machine
Single lever creep testing machine Multiple lever creep testing machine
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Different loading method machines Different loading method machines
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Explanation of Creep Data
Explanation of Creep Data
Generally, all creep and stress rupture related data are
Generally, all creep and stress rupture related data are
analyzed in terms of three variables: time, stress, and
analyzed in terms of three variables: time, stress, and
temperature. There are two important parameter should
temperature. There are two important parameter should
always be considered and calculate from creep testing
always be considered and calculate from creep testing
data: time to fracture (
data: time to fracture (
t
t
R R
), which is sometimes called
), which is sometimes called
creep lifetime and steady
creep lifetime and steady
-
-
state creep rate
state creep rate
c ( )

It is possible to calculate the It is possible to calculate the

creep lifetime creep lifetime ( (t t
R R
) by using the ) by using the
stress stress- -rupture time curve rupture time curve
shown. This curve permits to shown. This curve permits to
expect expect t t
R R
of the component for of the component for
particular combination of particular combination of
stress ( stress (o o) and temperature (T) ) and temperature (T)
as the time to rupture as the time to rupture t t
R R
is is
proportionally in linear proportionally in linear
relationship on log relationship on log- -log scale log scale
with the stress ( with the stress (o o) as shown ) as shown
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As shown in the figure for
Cr-Ni steel alloy. The
following equation can be
deduced from the figure:
R
t
m
= K
where t
R
= creep rupture
time in hours, o

= rupture
stress in MPa and K and m
constants can be found
from the figure .
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In the second stage of the
creep-time curve, the
creep rate becomes
approximately constant
and this stage is thereby
called steady state region
as shown in the figure.
The figure also indicates
that this stage has the
longest duration and the
steady-state creep rate can
be easily calculated
through the following
equation:
t
=
15
In fact, the creep rate can often be represented by the
Arrhenius relationship of the form:
A
n'
Q
exp
RT
| |

|
\ .
=
where A and n are constants; is usually in the range of 3
to 7 for metals and 1 to 2 for polymers; T is the
temperature in [K] and Q is called the activation energy
for creep in [J.mol
-1
] and it is mainly depending on the
material. The value of Q can be determined by plotting the
natural logarithm of the creep rate vs. (1/T). The data
should fall along a straight line
of slope
of slope
-
-
Q/R
Q/R where R is
the gas constant that equals to 8.314 [J.mol
-1
k
-1
] and. o is
the applied stress in [MPa].
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The shown figure
indicates the relationship
between creep stress and
the creep rate for carbon
steel at different
temperature. The figure
also suggests that the
creep strain rate would
correlate with the creep
stress through the
following equation:
n
t
= = B where B and n are constants
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The given equations give complete scope for the design
The given equations give complete scope for the design
based on the creep properties.
based on the creep properties.
In some application, it is required to define when the
In some application, it is required to define when the
component, which is subjected to creep, should be
component, which is subjected to creep, should be
replaced before failure. In this case the creep deformation
replaced before failure. In this case the creep deformation
itself is not important and then equation of
itself is not important and then equation of
t
t
R R
can be used
can be used
to calculate the creep lifetime for particular combination
to calculate the creep lifetime for particular combination
of stress and temperature for specific material, at which
of stress and temperature for specific material, at which
the component should be replaced before creep failure.
the component should be replaced before creep failure.
On the other hand, in some other applications, there is a
On the other hand, in some other applications, there is a
certain creep deformation value
certain creep deformation value
c
c

should not be
should not be
exceeded. In this case, equation of creep rate can be used
exceeded. In this case, equation of creep rate can be used
to decide when the component should be replaced before
to decide when the component should be replaced before
the creep strain reaches to the critical value.
the creep strain reaches to the critical value.
R
t
m
=K
n
B
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For the same propose of calculating the creep lifetime, a
For the same propose of calculating the creep lifetime, a
parameter called
parameter called
Larson and Miller
Larson and Miller
parameter
parameter
(
(
LM
LM
) have
) have
been given in the literature to facilities the calculation.
been given in the literature to facilities the calculation.
This parameter is in the following form:
This parameter is in the following form:
R
LM T C log t = +
where T is the temperature in [K]; C is material constant
where T is the temperature in [K]; C is material constant
usually in the range of
usually in the range of
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18
-
-
22 and in general is taken to
22 and in general is taken to
equal 20.
equal 20.
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In order to understand
LM equation,
let us
let us
estimate the creep
estimate the creep
rupture time for a
rupture time for a
Nimonic
Nimonic
80A at stress
80A at stress
of 300
of 300
MPa
MPa
and
and
temperature of 800
temperature of 800

C.
C.
The given figure shows
the relationship
between LM parameter
and logarithmic scale of
the applied creep stress
for Nimonic 80A and
Nimonic 105
From figure
LM =22.8x10
LM =22.8x10
3 3
at
o
o
=300
=300
MPa
MPa for
Nimonic
Nimonic
80A
80A
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By using LM parameter equation:
R
3
R
3
R
R
LM T C logt
22.8 10 800 273 20 logt
22.8 10
logt 20
800 273
t 17.74 Hours
= +
= + - +

=
+
=
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Exercise 5
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5.

From uniaxial

creep tests of a canvas-base laminated
plastic the following creep strains were found
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a) Plot the creep strain (e)-time (t) curves for each of
the stresses using the foregoing data
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b)

Obtain the approximate values of the creep rates and deduce the
constants B and n of the equation:
n
c o =

B
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6.

Using the Larson-Miller parameter for ductile cast
iron shown in Figure

2, determine the time required
before the metal fails at:
a)

an applied stress of 40 MPa

and temperature of 400 C and 600 C
b)

an applied stress of 80 MPa

and temperature of 400 C and 600 C
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a)

an applied stress of 40 MPa

and
temperature of 400 C and 600 C
( )
( )( )
( )( )
R
R
R
R
40 MPa
LM T logt
T
logt
t
logt
t
T
o =
= +
=
= +
~

= +
=
= ~
-3
-3
10 5
R
-3
at from the figure LM=20.35
20 10
at 400 C
20.35 400+273 20 10
=1.7310 Hours 2010 Years
20.35 20 10
204
at 600
4 Hours
C
600+273
85 Days

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b)

an applied stress of 80 MPa

and
temperature of 400 C and 600 C
( )
( )( )
( )( )
R
R
R
R
LM T logt
T
logt
t
logt
t
T
= +

=
=
= +
~

= +
= ~
-3
-3
8 3
R
-3
at = MPa from the figure LM=19
20 10
at 400 C
19 400+273 20 10
=1.7110 Hours 2010 Years
19 20 10
at 600
58 Hour
C
600
80
s 2.
+ 3
s
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5 Day