To investigate the mechanical properties and microstructure evolution of P92 steel during long-term service, the operated P92 main steam pipes from the first ultra-supercritical units in China were sectioned into samples representing various service durations and stresses (0# (as-received state, 1# (82,000 h, 67.3 MPa), 2# (85,000 h, 78.0 MPa), and 3# (100,000 h, 80.3 MPa)). Thereafter, a comprehensive assessment of their mechanical properties, including tensile strength, impact, hardness, and creep resistance, as well as a detailed microstructure analysis, was carried out. The effect of stress on the aging of material properties during operation is discussed. The results show that the circumferential stress caused by the increase in the internal steam pressure can significantly promote the creep life consumption of P92 steel, resulting in the degradation of mechanical properties and the expedited aging of the microstructure. The R_p0.2 and R_m of the P92 main steam pipe at room temperature and 605 °C decreased with the service time increase, reflecting the influence of stress in operation, which is expected to be used for the residual life evaluation of P92 steel. The relationship between the impact absorption energy (FATT50), Brinell hardness, and the operating time of P92 operating pipes is non-monotonic, indicating that these parameters are not sensitive indicators of material aging due to stress. The evaluation of performance degradation in P92 operating pipes due to stress-induced aging is not reliably discernible through optical metallography alone. To achieve a thorough assessment, the use of transmission electron microscopy (TEM) is essential.

P92 steel is widely used in ultra-supercritical units due to its excellent high-temperature performance. This paper studies the microstructure of P92 steel steam pipes in three conditions: as-supplied, after 80,000 h of service at 67.06 MPa stress, and after 100,000 h of service at 80.28 MPa stress. After prolonged service, the P92 steel retains its martensitic structure, but the lath width increases and the dislocation density decreases. In addition to M₂₃C₆, MX, and Laves phases, Z phase was also observed among the precipitates. The results indicate that the sizes of M₂₃C₆ and Laves phases increase with the progression of creep life consumption, with the coarsening rate of Laves phase being significantly higher than that of M₂₃C₆. However, the coarsening of MX phase is not evident. Compared to the Laves phase, the formation of the Z phase requires a longer period of time. The precipitation of the Z phase consumes MX carbonitrides, and it has been observed that the Z phase precipitates from the MX phase, with the two phases exhibiting a coexisting state.

The Laves phase formed during the long-term creep of 9% Cr heat-resistant steels plays an important role in their high-temperature mechanical properties. Detecting and quantifying the Laves phase is one of the main problems in predicting the creep residual life. This study detects and quantifies the Laves phase in various 9% Cr heat-resistant steel samples by anodic polarization. Both T92/P92 samples after creep and 9Cr ferritic martensitic samples after thermal ageing precipitate Laves phase particles, and the content of the Laves phase increases with the service time. Comparing the results obtained by the electrochemical method with those obtained by the traditional SEM observation method, it can be found that there is a similar two-stage linear relationship between the two results in all materials, which is related to the diameter change of Laves phase particles during service. According to the correlation between the Laves phase content and creep time, an extrapolation method for the prediction of the residual creep life is proposed. The results show that the creep life of P92 can be predicted by using the dissolved charge density of the Laves phase with high prediction accuracy. This method has the potential to evaluate the service states of materials and predict the long-term creep life in the industrial field.

The evolution of the microstructural and mechanical properties of alloy 617B during long-term service on a key-component test platform at 700 °C was systematically investigated. The precipitation behavior and size changes of the M₂₃C₆ and γ′ phases were characterized by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The results showed that carbide M₂₃C₆ precipitated in the form of discontinuous particles, plates, or needles at grain boundaries and within grains, while the γ′ phase had a spherical shape and was distributed in a dispersed manner. With prolonged service time, both the M₂₃C₆ and γ′ phases gradually coarsened. After 24,000 h of service, the yield strength, tensile strength, and Brinell hardness of alloy 617B significantly increased; however, the impact toughness decreased, accompanied by intergranular embrittlement. The increase in precipitate volume fraction and its contribution to the strength of the alloy were evaluated by a precipitation strengthening model. The coarsening of M₂₃C₆ was identified as the main cause of embrittlement. The findings of this study provide important experimental data and theoretical support for the stability of 617B alloys under long-term high-temperature service conditions.