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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c0046915
EISBN: 978-1-62708-232-7
... in.) deep with a 2.5-cm (1-in.) wall thickness, was a type 309 stainless steel weldment. Operating temperatures of the lead bath in the pan ranged from 805 deg C (1480 deg F) at the entry end to 845 deg C (1550 deg F) at the exit end. Analysis (visual inspection. metallographic analysis, moisture testing...
Abstract
Severely reduced wall thickness was encountered at the liquid line of a lead-bath pan that was used in a continuous strip or wire oil-tempering unit. Replacement of the pan was necessary after six months of service. The pan, 6.9 m (22.5 ft) long, 0.6 m (2 ft) wide, and 38 cm (15 in.) deep with a 2.5-cm (1-in.) wall thickness, was a type 309 stainless steel weldment. Operating temperatures of the lead bath in the pan ranged from 805 deg C (1480 deg F) at the entry end to 845 deg C (1550 deg F) at the exit end. Analysis (visual inspection. metallographic analysis, moisture testing, and etched micrographs using Murakami's reagent) supported the conclusions that thinning of the pan walls at the surface of the molten lead resulted from using coke of high moisture content and from the low fluctuating coke level. Recommendations included reducing the supply of oxygen attacking the grain boundaries and the hydrogen that readily promoted decarburization with the use of dry (2 to 3% moisture content) coke. Maintaining a thick layer of coke over the entire surface of molten lead in the pan would exclude atmospheric oxygen from the grain boundaries.
Image
in Heat Exchanger Corrosion in a Chlorinated Solvent Incinerator
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 3 Type 309 stainless steel support part after 1 year of service in a chlorinated solvent combustion incinerator.
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Image
in Heat Exchanger Corrosion in a Chlorinated Solvent Incinerator
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 4 Section from type 309 stainless steel support part showing heavy scale and internal attack. 81.3×.
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Image
in Heat Exchanger Corrosion in a Chlorinated Solvent Incinerator
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 6 Sectioned type 309 stainless steel test coupon. 130×.
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Image
in Crevice-Corrosion Failure of Evaporator Tubes Because of Defective Seam Welds
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 1 Section through a type 309S (Nb) stainless steel evaporator tube containing a defective seam weld. The cavity shown resulted from crevice corrosion and extended longitudinally below the inner surface of the weld. 60×
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Series: 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
... 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...
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.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001046
EISBN: 978-1-62708-214-3
... Abstract The thin plates within a type 309 stainless steel chlorinated solvent combustion preheater/heat exchanger designed to process fumes from a solvent coating process showed severe corrosion within 6 months of service. Within a year corrosion had produced holes in the plates, allowing...
Abstract
The thin plates within a type 309 stainless steel chlorinated solvent combustion preheater/heat exchanger designed to process fumes from a solvent coating process showed severe corrosion within 6 months of service. Within a year corrosion had produced holes in the plates, allowing gases to shunt across the preheater/exchanger. Metallographic examination of the plates showed that accelerated internal oxidation had been the cause of failure. Corrosion racks of candidate alloys (types 304, 309, and 316 stainless steels, Inconel 600, Inconel 625, Incoloy 800, Incoloy 825, and Inco alloy C-276) were placed directly in the hot gas stream, containing HCl and Cl2, for in situ testing. Results of this investigation showed that nickel-chromium corrosion-resistant alloys, such as Inconel 600, Inconel 625, and Inco alloy C-276, performed well in this environment. Laboratory testing of the same alloys, along with Inconel alloys 601, 617, and 690 and stainless steel type 347 was also conducted in a simulated waste incinerator nitrogen atmosphere containing 10% Co2, 9% O2, 4% HCl, 130 ppm HBr and 100 ppm SO2 at 595, 705, 815, and 925 deg C (1100, 1300,1500, and 1700 deg F). The tests confirmed the suitability of the nickel-chromium alloys for such an environment. Inconel 625 was selected for fabrication of a new preheater/exchanger.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0048835
EISBN: 978-1-62708-220-4
... welded to the base metal and all vessel welds were found to be overlaid with type 309 stainless steel. Long longitudinal cracks in the weld metal, as well as transverse cracks were exposed after the weld overlay was ground off. A decarburized region on either side of the crack was revealed...
Abstract
Welds in two CMo steel catalytic gas-oil desulfurizer reactors cracked under hydrogen pressure-temperature conditions that would not have been predicted by the June 1977 revision of the Nelson Curve for that material. Evidence of severe cracking was found in five weld-joint areas during examination of a naphtha desulfurizer by ultrasonic shear wave techniques. Defect indications were found in longitudinal and circumferential seam welds of the ASTM A204, grade A, steel sheet. The vessel was found to have a type 405 stainless steel liner for corrosion protection that was spot welded to the base metal and all vessel welds were found to be overlaid with type 309 stainless steel. Long longitudinal cracks in the weld metal, as well as transverse cracks were exposed after the weld overlay was ground off. A decarburized region on either side of the crack was revealed by metallurgical examination of a cross section of a longitudinal crack. It was concluded that the damage was caused by a form of hydrogen attack. Installation of a used Cr-Mo steel vessel with a type 347 stainless steel weld overlay was suggested as a corrective action.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001049
EISBN: 978-1-62708-214-3
... Abstract Routine inspections of a carbon steel wood pulp digester revealed a sharply increasing number of cracks in the overlay metal on the internal surface of the digester after 1 and 2 years of service. The weld overlay was composed of type 309 stainless steel on the top fourth...
Abstract
Routine inspections of a carbon steel wood pulp digester revealed a sharply increasing number of cracks in the overlay metal on the internal surface of the digester after 1 and 2 years of service. The weld overlay was composed of type 309 stainless steel on the top fourth of the digester and of a proprietary high-nickel material on the bottom three-fourths. Examination revealed three distinct modes of deterioration. General corrosion was linked to the use of unspecified overlay metal. Cracking resulted during installation from the use of a material susceptible to hot cracking. Deep corrosion fissures then developed at hot crack sites as a result of crevice corrosion. Use of the appropriate overlay material was recommended.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c9001223
EISBN: 978-1-62708-233-4
... Welding Society , New York . 2. Strauss B. , Schottky H. , Hinnüber J. , anorg Z. . allg. Chem. 188 ( 1930 ) 309 / 324 . 10.1002/zaac.19301880125 Selected References Selected References • Forms of Corrosion , Failure Analysis and Prevention , Vol 11 , ASM...
Abstract
The corner of a welded sheet construction made from austenitic corrosion-resistant chromium-nickel steel showed corrosive attack of the outer sheet. This attack was most severe at the points subjected to the greatest heat during welding. Particularly large amounts of weld metal had been applied. Microscopic examination showed grain disintegration was promoted by the thickness of the weld bead and the amount of heat required to produce it. If nonstabilized austenitic sheet is to be used in the future, one of the particularly low-carbon steels, X2 CrNi 18 9 or X2 CrNiMo 18 10, is recommended.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001387
EISBN: 978-1-62708-215-0
... electrodes and returned to service. Some of the cladding was also performed using E 309 stainless steel electrodes. Both cladding materials have completed 9 years of service without recurrence of the problem. Selected Reference Selected Reference • Forms of Corrosion , Failure Analysis...
Abstract
Nickel anodes failed in several electrolysis cells in a heavy-water upgrading plant. Dismantling of a cell revealed gouging and the presence of loosely attached black porous masses on the anode. The carbon steel top, plate was severely corroded. An appreciable quantity of black powder was also present on the bottom or the cell. SEM/EDX studies of the outer and inner surfaces of the gouged anode showed the presence of iron globules at the interface between the gouged and the unattacked anode. The chemical composition of the black powder was determined to be primarily iron. Cell malfunction was attributed to the accelerated dissolution of the carbon steel anode top, dislodgment of grains from the material, and subsequent closing of the small annular space between the anode and the cathode by debris from the anode top. Cladding of the carbon steel top with a corrosion-resistant material, such as nickel, nickel-base alloy, or stainless steel, was recommended.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001358
EISBN: 978-1-62708-215-0
... joint, showing lack of weld penetration Chemical Analysis/Identification Material and Weld Energy-dispersive x-ray analysis revealed that the base metal of the vanes was type 403 martensitic stainless steel. Analysis of the weld metal confirmed that the filler metal used was type 309...
Abstract
Several compressor diaphragms from five gas turbines cracked after a short time in service. The vanes were constructed of type 403 stainless steel, and welding was performed using type 309L austenitic stainless steel filler metal. The fractures originated in the weld heat-affected zones of inner and outer shrouds. A complete metallurgical analysis was conducted to determine the cause of failure. It was concluded that the diaphragms had failed by fatigue. Analysis suggests that the welds contained high residual stresses and had not been properly stress relieved. Improper welding techniques may have also contributed to the failures. Use of proper welding techniques, including appropriate prewelding and postwelding heat treatments, was recommended.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.med.c9001579
EISBN: 978-1-62708-226-6
.... 309 – 18 . 6. Pohler O.E.M. : in ASM Handbook , Vol. 11 , Failure Analysis and Prevention , ASM International , Materials Park, OH , 1995 , pp. 670 – 94 . 7. Spivak J.M. , Zuckerman J.D. , Kummer F.J. , and Frankel V.H. : J. Orthop. Trauma , vol. 5 ( 3...
Abstract
Stainless steel is frequently used for bone fracture fixation in spite of its sensitivity to pitting and cracking in chloride containing environments (such as organic fluids) and its susceptibility to fatigue and corrosion fatigue. A 316L stainless steel plate implant used for fixation of a femoral fracture failed after only 16 days of service and before bone callus formation had occurred. The steel used for the implant met the requirements of ASTM Standard F138 but did contain a silica-alumina inclusion that served as the initiation point for a fatigue/corrosion fatigue fracture. The fracture originated as a consequence of stress intensification at the edge of a screw hole located just above the bone fracture; several fatigue cracks were also observed on the opposite side of the screw hole edge. The crack propagated in a brittle-like fashion after a limited number of cycles under unilateral bending. The bending loads were presumably a consequence of leg oscillation during assisted perambulation.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001657
EISBN: 978-1-62708-227-3
... , Bradley E. F. , (ed.), ASM , Metals Park, Ohio , p. 309 ( 1979 ). 18. Koul A. K. and Wallace W. , private communication with Westinghouse Canada Inc. , May ( 1983 ). 19. Day M. F. and Thomas G. B. , High Temperature Alloys for Gas Turbines , Leige, Belgium...
Abstract
The circumstances surrounding the in-service failure of a cast Ni-base superalloy (Alloy 713LC) second stage turbine blade and a cast and coated Co-base superalloy (MAR-M302) first stage air-cooled vane in two turbine engines used for marine application are described. An overview of a systematic approach, analyzing the nature of degeneration and failure of the failed components, utilizing conventional metallurgical techniques, is presented. The topographical features of the turbine blade fracture surface revealed a fatigue-induced crack growth pattern, where crack initiation had taken place in the blade trailing edge. An estimate of the crack-growth rate for the stage II fatigue fracture region coupled with the metallographic results helped to identify the final mode of the turbine blade failure. A detailed metallographic and fractographic examination of the air-cooled vane revealed that coating erosion in conjunction with severe hot-corrosion was responsible for crack initiation in the leading edge area.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001004
EISBN: 978-1-62708-229-7
.... Ritche R.O. & Knott J.F. , Metall Trans , 5A ( 1974 ) pp 182 – 190 . 4. Briant C.L. & Banerji S.K. , Metall Trans. , 12A , ( 1981 ) pp 309 – 317 . 10.1007/BF02655204 5. Kupper J. , Erhart H. & Grabke H.J. , Corr. Science , 21 , ( 1981...
Abstract
The results of a failure analysis of a series of Cr-Mo-V steel turbine studs which had experienced a service lifetime of some 50,000 h are described. It was observed that certain studs suffered complete fracture while others showed significant defects located at the first stress bearing thread. Crack extension was the result of marked creep embrittlement and reverse temper embrittlement (RTE). Selected approaches were examined to assess the effects of RTE on the material toughness of selected studs. It was observed that Auger electron microscopy results which indicated the extent of grain boundary phosphorus segregation exhibited a good relationship with ambient temperature Charpy data. The electrochemical polarization kinetic reactivation, EPR, approach, however, proved disappointing in that the overlapping scatter in the minimum current density, Ir, for an embrittled and a non-embrittled material was such that no clear decision of the toughness properties was possible by this approach. The initial results obtained from small punch testing showed good agreement with other reported data and could be related to the FATT. Indeed, this small punch test, combined with a miniature sample sampling method, represents an attractive approach to the toughness assessment of critical power plant components.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001818
EISBN: 978-1-62708-241-9
...–Chromium Alloy Plate, Sheet, and Strip . ASTM Standard Specification B 409–01 . ASTM International , USA ( 2002 ) 4. American Society of Metals : Metallography and Microstructure . In: Metals Handbook , vol. 9 , 9th edn , pp. 309 – 316 . American Society of Metals, Metals Park, OH , USA...
Abstract
A sleeve-shaped fire shield that operates inside one of two burner trains in an oil and gas processing unit ruptured after 15 y of service. A detailed analysis was conducted to determine how and why the sleeve failed. The investigation included visual inspection, chemical and gas analysis, mechanical property testing, stereomicroscopy, and metallographic examination. The fire sleeves are fabricated from 3-mm thick plate made of Incoloy 800 rolled into 540-mm diam sections welded along the seam. Three such sections are joined together by circumferential welds to form a single 2.8 m sleeve. The findings from the investigation indicated that internal oxidation corrosion, driven by high temperatures, was the primary cause of failure. Prolonged exposure to temperatures up to 760 °C resulted in sensitization of the material, making it vulnerable to grain boundary attack. This led to significant deterioration of the grain boundaries, causing extensive grain loss (grain dropping) and the subsequent thinning of sleeve walls. Prior to failure, some portions of the sleeve were only 1.6 mm thick, nearly half their original thickness.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001609
EISBN: 978-1-62708-229-7
... with a matching type 430 Ti weld filler or austenitic stainless steel alloy type 309. Postweld heat treatment of the HRSG economizer harp assemblies requires close control of resistance heater, insulation, and thermocouple placement. To ensure an adequately wide heated band around each tube-to-header weld...
Abstract
Alloy 430 stainless steel tube-to-header welds failed in a heat recovery steam generator (HRSG) within one year of commissioning. The HRSG was in a combined cycle, gas-fired, combustion turbine electric power plant. Alloy 430, a 17% Cr ferritic stainless steel, was selected because of its resistance to chloride and sulfuric acid dewpoint corrosion under conditions potentially present in the HRSG low-pressure feedwater economizer. Intergranular corrosion and cracking were found in the weld metal and heat-affected zones. The hardness in these regions was up to 35 HRC, and the weld had received a postweld heat treatment (PWHT). Metallographic examination revealed that the corroded areas contained undertempered martensite. Fully tempered weld areas with a hardness of 93 HRB were not attacked. No evidence of corrosion fatigue was found. Uneven temperature control during PWHT was the most likely cause of failure.
Series: 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
... was performed using AISI 309 rod. Numerous areas of cracks, voids, and slag pockets were evident. Cracks originated in the weld nugget and propagated into the base material. Nickel-base welding rods are somewhat more difficult to use than stainless steel rods. When severe intergranular corrosion has occurred...
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.a0003568
EISBN: 978-1-62708-180-1
... Particle Erosion , Wear , Vol 61 , 1980 , p 309 – 324 65. Christman T. and Shewmon P.G. , Adiabatic Shear Localization and Erosion of Strong Aluminum Alloys , Wear , Vol 54 , 1979 , p 145 – 155 66. Sundararajan G. and Shewmon P.G. , A New Model...
Abstract
Erosion occurs as the result of a number of different mechanisms, depending on the composition, size, and shape of the eroding particles; their velocity and angle of impact; and the composition of the surface being eroded. This article describes the erosion of ductile and brittle materials with the aid of models and equations. It presents three examples of erosive wear failures, namely, abrasive erosion, erosion-corrosion, and cavitation erosion.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003542
EISBN: 978-1-62708-180-1
... , 1974 , p 309 – 322 • Mecholsky J.J. , Fracture Surface Analysis of Optical Fibers , Ceramics and Glasses , Vol 4 , Engineered Materials Handbook , ASM International , 1991 , p 663 – 668 • Mecholsky J.J. , Freiman S.W. , and Rice R.W. , Fracture Surface...
Abstract
Fractography is the means and methods for characterizing a fractured specimen or component. This includes the examination of fracture-exposed surfaces and the interpretation of the fracture markings as well as the examination and interpretation of crack patterns. This article describes the former of these two parts of fractography. It presents the techniques of fractography and explains fracture markings using glass and ceramic examples. The article also discusses the fracture modes in ceramics and provides examples of fracture origins.
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