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304 (austenitic wrought stainless steel)
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Book Chapter
Boiler Stack Economizer Tube Failure
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001825
EISBN: 978-1-62708-241-9
... longitudinal and transverse cracks SEM/EDS fracture surface analysis tensile stress 304 (austenitic wrought stainless steel) UNS S30400 Introduction This paper details the investigation of the failure of a tube from a boiler stack economizer. The economizer was in a boiler at an ethanol plant...
Abstract
A type 304 stainless steel tube that failed in a boiler stack economizer was analyzed to determine the cause. The investigation consisted of visual, SEM/EDS, and metallographic analysis. Several degradation mechanisms appeared to be at work, including pitting corrosion, chloride stress corrosion cracking, and fatigue fracture. Investigators concluded that the primary failure mechanism was fatigue fracture, although either of the other mechanisms may have eventually caused the tube to fail in the absence of fatigue.
Book Chapter
Structural Instability of Cold Worked Alloy 304 in 650 °C Service
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001581
EISBN: 978-1-62708-235-8
... – 10.50 10.50 – 13.00 Molybdenum 0.18 0.16 — — Nitrogen 0.022 0.026 — — (a) Type 304L has a max. carbon of 0.035% with nickel of 8.00 to 12.00%. Type 304H has carbon of 0.04 to 0.10%. Wrought austenitic stainless steels, such as alloys 304L, 304, and 304H, have essentially...
Abstract
A heavily worked 304 stainless steel wire basket recrystallized and distorted while in service at 650 deg C (1200 deg F). This case study demonstrates that heavily cold worked austenitic stainless steel components can experience large losses in creep strength, and potentially structural collapse, under elevated temperature service, even at temperatures more than 300 deg C (540 deg F) below the normal solution annealing temperature. The creep strength of the recrystallized 304/304L steel was more than 1000 times less than that achievable with solution annealed 304H. These observations are consistent with limitations (2000 Addendum to ASME Boiler and Pressure Vessel Code) on the use of cold worked austenitic stainless steels for elevated temperature service.
Book Chapter
Biologically Influenced Corrosion of Stainless Steel Welds by Water
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001683
EISBN: 978-1-62708-234-1
... Abstract Corrosion in a closed-loop cooling water system constructed of austenitic stainless steel occurred during an extended lay up of the system with biologically contaminated water. The characteristics of the failure were those of microbiologically influenced corrosion (MIC). The corrosion...
Abstract
Corrosion in a closed-loop cooling water system constructed of austenitic stainless steel occurred during an extended lay up of the system with biologically contaminated water. The characteristics of the failure were those of microbiologically influenced corrosion (MIC). The corrosion occurred at welds and consisted of large subsurface void formations with pinhole penetrations of the surfaces. Corrosive attack initiated in the heat affected zones of the welds, usually immediately adjacent to fusion lines. Stepwise grinding, polishing, and etching through the affected areas revealed that voids generally grew in the wrought material by uniform general corrosion. Tunneling or worm-holing was also observed, whereby void extension occurred by initiating daughter voids probably at flaws or other inhomogeneities. Selective attack occurred within the fusion zone, i.e., within the cast two-phase structure of the weld filler itself. The result was a void wall which consisted of a rough and porous ferritic material, a consequence of preferential attack of the austenitic phase and slightly lower rate of corrosive attack of the ferrite phase. The three-dimensional spongy surface was studied optically and with the scanning electron microscope.
Book Chapter
Failure Analysis of AISI-304 Stainless Steel Styrene Storage Tank
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001770
EISBN: 978-1-62708-241-9
... a postweld heat treatment to remove weld sensitization and minimize residual stresses. storage tank corrosion welding defects stainless steel transgranular cracks fractography impact absorbed energy AISI 304 (austenitic stainless steel) UNS S30400 AISI 308 (austenitic stainless steel) UNS...
Abstract
A storage tank had been in service at a petrochemical plant for 13 years when inspectors discovered cracks adjacent to weld joints and in the base plate near the foundation. The tank was made from AISI 304 stainless steel and held styrene monomer, a derivative of benzene. The cracks were subsequently welded over with 308 stainless steel filler wire and the base plate was replaced with new material. Soon after, the tank began leaking along the weld bead, triggering a full-scale investigation; spectroscopy, optical and scanning electron microscopy, fractography, SEM-EDS analysis, and microhardness, tensile, and impact testing. The results revealed transgranular cracks in the HAZ and base plate, likely initiated by stresses developed during welding and the presence of chloride from seawater used in the plant. It was also found that the repair weld was improperly done, nor did it include a postweld heat treatment to remove weld sensitization and minimize residual stresses.
Book Chapter
Microfractography and Metallography for Failure Analysis
Available to PurchaseSeries: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006760
EISBN: 978-1-62708-295-2
... perpendicular to the main axis of the component, as shown in Fig. 9 . Generally, a high amount of deformation of the structure will take place before separation. Fig. 9 (a) Shear test of austenitic stainless steel. (b) High amount of deformation. Beginning of separation in 304 stainless steel. Marble’s...
Abstract
Visual examination, using the unaided eye or a low-power optical magnifier, is typically one of the first steps in a failure investigation. This article presents the guidelines for selecting samples for scanning electron microscope examination and optical metallography and for cleaning fracture surfaces. It discusses damage characterization of metals, covering various factors that influence the damage, namely stress, aggressive environment, temperature, and discontinuities.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003570
EISBN: 978-1-62708-180-1
... at lath boundaries. (b) Early stage of material removal Fig. 3 Vibratory cavitation erosion of type 304 austenitic stainless steel. (a) Linear deformation features and boundary definition. (b) Material removal at upheaved grain boundary Fig. 4 Striated fracture surface in type 304...
Abstract
Erosion of solid surfaces can be brought about solely by liquids in two ways: from damage induced by formation and subsequent collapse of voids or cavities within the liquid, and from high-velocity impacts between a solid surface and liquid droplets. The former process is called cavitation erosion and the latter is liquid-droplet erosion. This article emphasizes on manifestations of damage and ways to minimize or repair these types of liquid impact damage, with illustrations.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001536
EISBN: 978-1-62708-229-7
... into the reactor pressure vessel in the event of a loss-of-coolant accident, and under normal operating conditions, it is filled with more or less stagnant cooling water at a temperature of 205 to 260 °C (400 to 500 °F) and a pressure of 6.9 MPa (1000 psi). In addition to wrought type 304 stainless steel piping...
Abstract
Argonne National Laboratory has conducted analyses of failed components from nuclear power-generating stations since 1974. The considerations involved in working with and analyzing radioactive components are reviewed here, and the decontamination of these components is discussed. Analyses of four failed components from nuclear plants are then described to illustrate the kinds of failures seen in service. The failures discussed are (1) intergranular stress-corrosion cracking of core spray injection piping in a boiling water reactor, (2) failure of canopy seal welds in adapter tube assemblies in the control rod drive head of a pressurized water reactor, (3) thermal fatigue of a recirculation pump shaft in a boiling water reactor, and (4) failure of pump seal wear rings by nickel leaching in a boiling water reactor.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003553
EISBN: 978-1-62708-180-1
... rolled, extruded, or forged products are stressed in the short-transverse direction. In wrought austenitic stainless steels, crack paths are usually transgranular if proper heat treatment has been employed. However, if thermal processing has produced sensitization because of carbide precipitation...
Abstract
This article commences with a discussion on the characteristics of stress-corrosion cracking (SCC) and describes crack initiation and propagation during SCC. It reviews the various mechanisms of SCC and addresses electrochemical and stress-sorption theories. The article explains the SCC, which occurs due to welding, metalworking process, and stress concentration, including options for investigation and corrective measures. It describes the sources of stresses in service and the effect of composition and metal structure on the susceptibility of SCC. The article provides information on specific ions and substances, service environments, and preservice environments responsible for SCC. It details the analysis of SCC failures, which include on-site examination, sampling, observation of fracture surface characteristics, macroscopic examination, microscopic examination, chemical analysis, metallographic analysis, and simulated-service tests. It provides case studies for the analysis of SCC service failures and their occurrence in steels, stainless steels, and commercial alloys of aluminum, copper, magnesium, and titanium.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001808
EISBN: 978-1-62708-241-9
... of poor operations or improper materials selection, and thus often preventable. heat exchangers drain lines corrosion bacterial growth copper stainless steel pitting perforations microscopy corrosion resistance 304L stainless steel (austenitic wrought stainless steel) UNS S30403 316L...
Abstract
Six cases of failure attributed to microbiologically influenced corrosion (MIC) were analyzed to determine if any of the failures could have been avoided or at least predicted. The failures represent a diversity of applications involving typical materials, primarily stainless steel and copper alloys, in contact with a variety of liquids, chemistries, and substances. Analytical techniques employed include stereoscopic examination, energy dispersive x-ray spectroscopy (EDS), temperature and pH testing, and metallographic analysis. The findings indicate that MIC is frequently the result of poor operations or improper materials selection, and thus often preventable.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006785
EISBN: 978-1-62708-295-2
... cracking Alloy Environment Carbon steel Hot nitrate, hydroxide, and carbonate/bicarbonate solutions High-strength steels Aqueous electrolytes, particularly when containing H 2 S Austenitic stainless steels Hot, concentrated chloride solutions; chloride-contaminated steam; hot...
Abstract
Stress-corrosion cracking (SCC) is a form of corrosion and produces wastage in that the stress-corrosion cracks penetrate the cross-sectional thickness of a component over time and deteriorate its mechanical strength. Although there are factors common among the different forms of environmentally induced cracking, this article deals only with SCC of metallic components. It begins by presenting terminology and background of SCC. Then, the general characteristics of SCC and the development of conditions for SCC as well as the stages of SCC are covered. The article provides a brief overview of proposed SCC propagation mechanisms. It discusses the processes involved in diagnosing SCC and the prevention and mitigation of SCC. Several engineering alloys are discussed with respect to their susceptibility to SCC. This includes a description of some of the environmental and metallurgical conditions commonly associated with the development of SCC, although not all, and numerous case studies.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001819
EISBN: 978-1-62708-180-1
... a soft austenitic 304 stainless steel and exhibited minimal surface corrosion. The corrosion products of the plate impregnate the surrounding tissues, as seen on the microprobe analysis shown in Fig. 6(c) . Fig. 6 Failed historic Lane plate. (a) Heavily corroded Lane plate from chromium steel...
Abstract
This article commences with a description of the prosthetic devices and implants used for internal fixation. It describes the complications related to implants and provides a list of major standards for orthopedic implant materials. The article illustrates the body environment and its interactions with implants. The considerations for designing internal fixation devices are also described. The article analyzes failed internal fixation devices by explaining the failures of implants and prosthetic devices due to implant deficiencies, mechanical or biomechanical conditions, and degradation. Finally, the article discusses the fatigue properties of implant materials and the fractures of total hip joint prostheses.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003520
EISBN: 978-1-62708-180-1
..., for example, austenite or retained austenite, ferrite, delta ferrite or martensite, sigma, and carbides in steels. Perform simulation tests to evaluate critical characteristics of the material (such as the stress-corrosion cracking tendency in a particular environment), to determine the degree...
Abstract
This article outlines the basic steps to be followed and the range of techniques available for failure analysis, namely, background data assembling, visual examination, microfractography, chemical analysis, metallographic examination, electron microscopy, electron microprobe analysis, X-ray techniques, and simulations. It also describes the steps for analyzing the data, preparing the report, preservation of evidence, and follow-up on recommendations.
Book Chapter
Forms of Corrosion
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... aluminum alone normally is not polarized to its pitting potential. In many environments, aluminum can be used in contact with chromium or stainless steels with only slight acceleration of corrosion; chromium and stainless steels are easily polarized cathodically in mild environments, so...
Abstract
This article addresses the forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. It describes the mechanisms of corrosive attack for specific forms of corrosion such as galvanic corrosion, uniform corrosion, pitting and crevice corrosion, intergranular corrosion, and velocity-affected corrosion. The article contains a table that lists combinations of alloys and environments subjected to selective leaching and the elements removed by leaching.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
.... Corrosion of aluminum in contact with more cathodic metals is much less severe in solutions of most nonhalide salts, in which aluminum alone normally is not polarized to its pitting potential. In many environments, aluminum can be used in contact with chromium or stainless steels with only slight...
Abstract
Corrosion is the electrochemical reaction of a material and its environment. This article addresses those forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. Various forms of corrosion covered are galvanic corrosion, uniform corrosion, pitting, crevice corrosion, intergranular corrosion, selective leaching, and velocity-affected corrosion. In particular, mechanisms of corrosive attack for specific forms of corrosion, as well as evaluation and factors contributing to these forms, are described. These reviews of corrosion forms and mechanisms are intended to assist the reader in developing an understanding of the underlying principles of corrosion; acquiring such an understanding is the first step in recognizing and analyzing corrosion-related failures and in formulating preventive measures.
Book Chapter
Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades in a Circulating Water Pump
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001082
EISBN: 978-1-62708-214-3
... Abstract Several large-diameter type 304L stainless steel impeller/propeller blades in a circulating water pump failed after approximately 8 months of operation. The impeller was a single casting that had been modified with a fillet weld buildup at the blade root. Visual examination indicated...
Abstract
Several large-diameter type 304L stainless steel impeller/propeller blades in a circulating water pump failed after approximately 8 months of operation. The impeller was a single casting that had been modified with a fillet weld buildup at the blade root. Visual examination indicated that the fracture originated near the blade-to-hub attachment in the area of the weld buildup. Specimens from four failed castings and from an impeller that had developed cracks prior to design modification were subjected to a complete analysis. A number of finite-element-method computer models were also constructed. It was determined that the blades failed by fatigue that had been accelerated by stress-corrosion cracking. The mechanism of failure was flow-induced vibration, in which the vortex-shedding frequencies of the blades were attuned to the natural frequency of the blade/hub configuration. A number of solutions involving material selection and impeller redesign were recommended.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001816
EISBN: 978-1-62708-180-1
...×. Mottled areas in both specimens are regions where pearlite has decomposed into ferrite and spheroidal carbides. Both etched with 2% nital Austenitic stainless steels can generally exhibit three types of metallurgical instability at elevated temperatures: carbide formation or modification, ferrite...
Abstract
This article explains the main types and characteristic causes of failures in boilers and other equipment in stationary and marine power plants that use steam as the working fluid with examples. It focuses on the distinctive features of each type that enable the failure analyst to determine the cause and suggest corrective action. The causes of failures include tube rupture, corrosion or scaling, fatigue, erosion, and stress-corrosion cracking. The article also describes the procedures for conducting a failure analysis.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001818
EISBN: 978-1-62708-180-1
... Treatment <xref rid="a0001818-ref2" ref-type="bibr">(Ref 2)</xref> During a routine maintenance procedure at a power station, dye-penetrant examination revealed linear indications on the outer surface of a cross in a piping system. The cross was specified as SA403 type WP 304 stainless steel that had...
Abstract
This article discusses the effect of using unsuitable alloys, metallurgical discontinuities, fabrication practices, and stress raisers on the failure of a pressure vessel. It provides information on pressure vessels made of composite materials and their welding practices. The article explains the failure of pressure vessels with emphasis on stress-corrosion cracking, hydrogen embrittlement, brittle and ductile fractures, creep and stress rupture, and fatigue with examples.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006828
EISBN: 978-1-62708-329-4
... Embrittlement in Fuel Line Braze Joints An instance of LMIE occurred during the manufacture of automobile engine fuel lines ( Ref 15 ). The austenitic stainless steel tube of the fuel line reportedly fractured during the brazing process, with a complete separation of the tube at the fillet of the low...
Abstract
The various methods of furnace, torch, induction, resistance, dip, and laser brazing are used to produce a wide range of highly reliable brazed assemblies. However, imperfections that can lead to braze failure may result if proper attention is not paid to the physical properties of the material, joint design, prebraze cleaning, brazing procedures, postbraze cleaning, and quality control. Factors that must be considered include brazeability of the base metals; joint design and fit-up; filler-metal selection; prebraze cleaning; brazing temperature, time, atmosphere, or flux; conditions of the faying surfaces; postbraze cleaning; and service conditions. This article focuses on the advantages, limitations, sources of failure, and anomalies resulting from the brazing process. It discusses the processes involved in the testing and inspection required of the braze joint or assembly.
Book Chapter
Failures of Pressure Vessels and Process Piping
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006812
EISBN: 978-1-62708-329-4
... is involved. As an example of improper material specification or use, galvanized steel clips were welded to austenitic stainless steel piping. The galvanized (zinc) coating became molten during the welding process, and the liquid zinc attacked the grain boundaries under shrinkage stresses in the stainless...
Abstract
This article discusses pressure vessels, piping, and associated pressure-boundary items of the types used in nuclear and conventional power plants, refineries, and chemical-processing plants. It begins by explaining the necessity of conducting a failure analysis, followed by the objectives of a failure analysis. Then, the article discusses the processes involved in failure analysis, including codes and standards. Next, fabrication flaws that can develop into failures of in-service pressure vessels and piping are covered. This is followed by sections discussing in-service mechanical and metallurgical failures, environment-assisted cracking failures, and other damage mechanisms that induce cracking failures. Finally, the article provides information on inspection practices.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003501
EISBN: 978-1-62708-180-1
..., stainless steel, age-hardening aluminum alloys, etc.), its general product form (e.g., wrought, cast, powder metallurgy, etc.), and the processing method (e.g., forged, die cast, injection molded, etc.). All of these factors must be considered when the shape of a part is defined during configuration design...
Abstract
Materials selection is an important engineering function in both the design and failure analysis of components. This article briefly reviews the general aspects of materials selection as a concern in proactive failure prevention during design and as a possible root cause of failed parts. It discusses the overall concept of design and describes the role of the materials engineer in the design and materials selection process. The article highlights the significance of materials selection in both the prevention and analysis of failures.
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