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D.K. Bhattacharya, J.B. Ghanamoorthy, Baldev Raj
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Philip J. Kenny
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Samuel J. Brown, Edward V. Bravenec
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K.E. Perumal
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Book Chapter
Transgranular Stress-Corrosion Cracking Failures in AISI 304L Stainless Steel Dished Ends During Storage
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001319
EISBN: 978-1-62708-215-0
... Abstract Several type 304L stainless steel dished ends used in the fabrication of cylindrical vessels developed extensive cracking during storage. All of the dished ends had been procured from a single manufacturer and belonged to the same batch. When examined visually, several rust marks were...
Abstract
Several type 304L stainless steel dished ends used in the fabrication of cylindrical vessels developed extensive cracking during storage. All of the dished ends had been procured from a single manufacturer and belonged to the same batch. When examined visually, several rust marks were observed, indicating contamination by rusted carbon steel particles. Liquid penetrant testing was used to determine the extent of the cracks, and in situ metallographic analysis was performed over the cracked region. The morphology of the cracks was indicative of transgranular stress-corrosion cracking (TGSCC). Conditions promoting the occurrence of the TGSCC included significant tensile stresses on the inside of the dished ends, the presence of surface contamination by iron due to poor handling practice using carbon steel implements, and storage in a coastal environment with an average temperature of 25 to 32 deg C (77 to 90 deg F), an average humidity ranging from 70 to 80%, and an atmospheric NaCl content ranging from 8 to 45 mg/m2 /day. Recommendations preventing further occurrence of the situation were strict avoidance of the use of carbon steel handling implements, strict avoidance of cleaning practices that cause long-term exposure to chlorine-containing cleaning fluid, and solution annealing of the dished ends at 1050 deg C (1920 deg F) for 1 h followed by water quenching to relieve residual stresses.
Book Chapter
Failure of a Buried Type 304L Stainless Steel Drain Line by Galvanic Attack
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0046535
EISBN: 978-1-62708-234-1
... Abstract One of five underground drain lines intended to carry a highly acidic effluent from a chemical-processing plant to distant holding tanks failed in just a few months. Each line was made of 304L stainless steel pipe 73 mm (2 in.) in diam with a 5 mm (0.203 in.) wall thickness. Lengths...
Abstract
One of five underground drain lines intended to carry a highly acidic effluent from a chemical-processing plant to distant holding tanks failed in just a few months. Each line was made of 304L stainless steel pipe 73 mm (2 in.) in diam with a 5 mm (0.203 in.) wall thickness. Lengths of pipe were joined by shielded metal arc welding. Soundness of the welded joints was determined by water back-pressure testing after several lengths of pipe had been installed and joined. Before completion of the pipeline, a pressure drop was observed during back-pressure testing. An extreme depression in the backfill revealed the site of failure. Analysis (visual inspection, electrical conductivity, and soil analysis) supported the conclusions that the failure had resulted from galvanic corrosion at a point where the corrosivity of the soil was substantially greater than the average, resulting in a voltage decrease near the point of failure of about 1.3 to 1.7 V. Recommendations included that the pipelines be asphalt coated and enclosed in a concrete trough with a concrete cover. Also, magnesium anodes, connected electrically to each line, should be installed at periodic intervals along their entire length to provide cathodic protection.
Image
in Stress-Corrosion Cracking of Stainless Steel Heat Exchanger Tubes in a Fertilizer Plant
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 2 Transgranular SCC of type 304L stainless steel tubes by chloride. 200×.
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Image
Typical microstructure of solution-annealed type 304L stainless steel. 142....
Available to PurchasePublished: 01 December 1992
Fig. 5 Typical microstructure of solution-annealed type 304L stainless steel. 142.2×.
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Image
in Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades in a Circulating Water Pump
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 5 Samples 4 and 5 prior to removal from type 304L impeller.
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Image
As-cast type 304L microstructure near blade-to-hub attachment (sample 4). O...
Available to Purchase
in Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades in a Circulating Water Pump
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 13 As-cast type 304L microstructure near blade-to-hub attachment (sample 4). Oxalytic acid electrolytic etch. 62×.
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Image
As-cast type 304L microstructure from blade trailing edge (sample 5). Oxaly...
Available to Purchase
in Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades in a Circulating Water Pump
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 14 As-cast type 304L microstructure from blade trailing edge (sample 5). Oxalytic acid electrolytic etch. 77×.
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Image
Cross section of as-cast type 304L blade. Leading edge (sample 1). No crack...
Available to Purchase
in Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades in a Circulating Water Pump
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 16 Cross section of as-cast type 304L blade. Leading edge (sample 1). No cracking is visible. Etched in Marble's reagent. 65×.
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Image
Cross section of type 304L blade (sample 4), showing cracks in base metal a...
Available to Purchase
in Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades in a Circulating Water Pump
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 17 Cross section of type 304L blade (sample 4), showing cracks in base metal and in weld repairs at hub-to-blade attachment.
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Image
SCC initiated on the liquor side in the type 304L base metal and E308 weldm...
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in Stress-Corrosion Cracking of a Pandia Digester Inlet Cone
> ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment
Published: 01 June 2019
Fig. 3 SCC initiated on the liquor side in the type 304L base metal and E308 weldment. Magnification 3×
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Image
Normal microstructure of AISI 304L austenitic stainless steel (etched with ...
Available to Purchase
in Bacterial-Induced Corrosion of AISI Type 304 Stainless Steel Tanks
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 1 Normal microstructure of AISI 304L austenitic stainless steel (etched with oxalic acid solution, 500×).
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Image
Normal microstructure of the heat-affected zone in the AISI 304L stainless ...
Available to Purchase
in Bacterial-Induced Corrosion of AISI Type 304 Stainless Steel Tanks
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 2 Normal microstructure of the heat-affected zone in the AISI 304L stainless steel tank (etched with oxalic acid solution, 500×).
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Image
Appearance of pits adjacent to welds in the AISI 304L stainless steel tank ...
Available to Purchase
in Bacterial-Induced Corrosion of AISI Type 304 Stainless Steel Tanks
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 3 Appearance of pits adjacent to welds in the AISI 304L stainless steel tank (etched with oxalic acid solution, 3.5×).
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Image
Appearance of pits in the bottom of the AISI 304L tank bottom (unetched, tr...
Available to Purchase
in Bacterial-Induced Corrosion of AISI Type 304 Stainless Steel Tanks
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 4 Appearance of pits in the bottom of the AISI 304L tank bottom (unetched, true size).
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Book Chapter
Crevice-Corrosion Failure of Evaporator Tubes Because of Defective Seam Welds
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0047611
EISBN: 978-1-62708-220-4
... tubes expanded and welded into two type 304L stainless steel tube sheets. The tubes failed by crevice corrosion. The failed tubes were defective as-received, and the establishment of concentration cells within the longitudinal cracks in the seam welds led to ultimate corrosive penetration of the wall...
Abstract
Several tubes in a tube bundle in an evaporator used to concentrate an acid nitrate solution failed by leakage. The feed to the evaporator contained about 6% nitrate, and the discharge about 60% nitrate. The tube bundle was comprised of type 309S (Nb) stainless steel drawn-and-welded tubes expanded and welded into two type 304L stainless steel tube sheets. The tubes failed by crevice corrosion. The failed tubes were defective as-received, and the establishment of concentration cells within the longitudinal cracks in the seam welds led to ultimate corrosive penetration of the wall. There was no evidence of crevice corrosion or any localized penetration of tubes that had sound welds. The leaking type 309S (Nb) welded tubes should be replaced with seamless tubes of type 304L stainless steel to minimize the areas requiring welding and to provide maximum weldability for the tube-sheet joints.
Book Chapter
Bacterial-Induced Corrosion of AISI Type 304 Stainless Steel Tanks
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001655
EISBN: 978-1-62708-220-4
... Abstract This investigation involved two AISI 304L acid storage tanks and one AISI 304L spent solvent tank from a sewage treatment facility. After installation, these tanks were hydrostatically tested using sewage effluent. No leaks were found and after a year or two, the tanks were drained...
Abstract
This investigation involved two AISI 304L acid storage tanks and one AISI 304L spent solvent tank from a sewage treatment facility. After installation, these tanks were hydrostatically tested using sewage effluent. No leaks were found and after a year or two, the tanks were drained and filled with nitric acid in preparation for service. Three weeks later the two acid tanks were found to be leaking from the bottom. Samples from the spent solvent tank revealed that pitting was located in a depressed area near a suction hole, beneath a black residue. It was concluded that the acid tanks failed by chloride-induced pitting initiated by microbial activity. Further, the spent solvent tank failed by a similar, but anaerobic mechanism. The use of the effluent for the hydrostatic test and the failure to remove it and clean and dry the tanks was the primary cause of failure. Localized carbide segregation in the original plate served as preferential corrosion sites. Had the tanks been hydrostatically tested in a proper manner, the pitting may not have occurred.
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.
Book Chapter
Stress-Corrosion Cracking of Stainless Steel Heat Exchanger Tubes in a Fertilizer Plant
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001048
EISBN: 978-1-62708-214-3
... Abstract Several type 304L (UNS S30400) stainless steel seamless tubes in a high-pressure synthesis gas cooler condensing ammonia in a fertilizer plant leaked in an unexpectedly short time. Representative samples of the tubes were subjected to chemical analysis, hardness tests, and optical...
Abstract
Several type 304L (UNS S30400) stainless steel seamless tubes in a high-pressure synthesis gas cooler condensing ammonia in a fertilizer plant leaked in an unexpectedly short time. Representative samples of the tubes were subjected to chemical analysis, hardness tests, and optical microscopy examination. The tests revealed that the tubes conformed to specification. Crack morphology indicated stress-corrosion cracking by chlorides present in the cooling water. Use of a duplex stainless steel (for example, UNS S32304 S31803) as a tube material was recommended.
Book Chapter
Galvanic Corrosion Failure of Austenitic Stainless Steel Pipe Flange Assemblies
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001336
EISBN: 978-1-62708-215-0
... Abstract Catastrophic pitting corrosion occurred in type 304L stainless steel pipe flange assemblies in an industrial food processor. During regular service the pumped medium was pureed vegetables. In situ maintenance procedures included cleaning of the assemblies with a sodium hypochlorite...
Abstract
Catastrophic pitting corrosion occurred in type 304L stainless steel pipe flange assemblies in an industrial food processor. During regular service the pumped medium was pureed vegetables. In situ maintenance procedures included cleaning of the assemblies with a sodium hypochlorite solution. It was determined that the assemblies failed due to an austenite-martensite galvanic couple activated by a chlorine bearing electrolyte. The martensitic areas resulted from a transformation during cold-forming operations. Solution annealing after forming, revision of the design of the pipe flange assemblies to eliminate the forming operation, and removal of the source of chlorine were recommended.
Book Chapter
Stress-Corrosion Cracking in Stainless Steel Heater Sheathing
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001390
EISBN: 978-1-62708-215-0
... Abstract Cracking occurred in type 304L stainless steel sheaths on nichrome wire heaters that had been in storage for about 5 years in a coastal atmosphere. The cracks were discovered when the heater coils were removed from storage in their original polyethylene packing materials...
Abstract
Cracking occurred in type 304L stainless steel sheaths on nichrome wire heaters that had been in storage for about 5 years in a coastal atmosphere. The cracks were discovered when the heater coils were removed from storage in their original polyethylene packing materials and straightened for use. Fractography established that fracture occurred by stress-corrosion cracking. The cracks originated at rusted areas on the cladding that occurred under iron particles left on the surface during manufacture. High hardness values indicated that solution annealing following cold working had not been carried out as specified. It was recommended that the sheathing material be fully annealed and that the outer surface be pickled and passivated.
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