The microstructure and residual mechanical properties of several groups of T92/Super304H dissimilar steel welded joints (hereinafter referred to as welded joints) in service for 70,000~85,000 h were analyzed. The results show that the early service history of the welded joint results in the polygonization of the martensite lath and the coarsening of the precipitated phase on the side of T92 steel. In the further creep process, the cavities nucleate along the precipitated phase interface and the triple junction grain boundary. Under the same load, the creep life of the joint decreases rapidly with the increase in service time and, finally, type IV cracking occurs. Type IV cracking needs to meet two conditions: 1. a large degree of precipitated phase coarsening and cavity nucleation in the fine grain heat-affected zone (FGHAZ) and 2. a much lower loading stress than the yield strength.

This work aims to study the effect of pre-strain on the fracture behavior of X80 pipeline girth weld joint, a comprehensive analysis was conducted on the microstructure and mechanical properties of the girth weld before and after pre-strain treatment. The mechanical properties were evaluated through tensile testing, Charpy impact testing, and digital image correlation (DIC) strain analysis. Furthermore, the microstructure and fracture morphology of the girth weld were observed using optical electron microscopy (OM) and scanning electron microscopy (SEM). The results show that the application of pre-strain treatment leads to dislocation accumulation at the grain boundary of X80 pipeline girth weld, resulting in stress concentration and subsequent formation of damage holes. This process disrupts the continuity of chain M-A island and initiates small cracks at the grain boundary, ultimately causing a significant decrease in impact toughness and impact work from 177 J to about 10 J.

P91 steel and P91 steel joints experience performance degradation after serving for 30,000 h in working conditions. To clarify the damage and failure behavior and remaining life of the joints during subsequent service, further creep testing was conducted on the welded joints of P91 steel that had been in service for 30,000 h at three temperatures: 550 °C, 575 °C, and 600 °C. The fracture surface and the cross-section damage behavior were characterized by SEM and EBSD methods. The results show that there are two types of fracture modes in the joints at different temperatures: ductile cracking occurring at the BM, and type IV cracking occurring in the FGHAZ. The threshold stress for fracture mode transition decreases with an increase in working temperature. Type IV cracking near the HAZ is the main reason for the premature failure of joints during service. And based on the fracture mode, the dual-constant L-M method was proposed to predict the strength of in-service joint materials. The testing data are discussed and classified based on the fracture mode in this method, which has high accuracy and can prevent the premature failure of joints.