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Two portions of a modified type 403 stainless steel steam turbine blade dam...
Available to PurchasePublished: 01 January 2002
Fig. 9 Two portions of a modified type 403 stainless steel steam turbine blade damaged by liquid impingement erosion. The portion at left was protected by a shield of 1 mm (0.04 in.) thick rolled Stellite 6B brazed onto the leading edge of the blade; the portion at right was unprotected
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Image
A single-origin corrosion-fatigue crack in type 403 stainless steel exposed...
Available to PurchasePublished: 01 January 2002
Fig. 22 A single-origin corrosion-fatigue crack in type 403 stainless steel exposed to steam showing rubbed origin (arrow) and beach marks. Scanning electron fractograph (secondary electron image). 60×
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Image
Micrograph of type 403 stainless steel as-forged. The microstructure is pre...
Available to PurchasePublished: 01 January 2002
Fig. 31 Micrograph of type 403 stainless steel as-forged. The microstructure is predominantly a mixture of carbide particles in a matrix of ferrite. No evidence of quenching and tempering was observed. High- and low-temperature oxidation can be observed on the surface of the sample and within
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Image
Micrograph of type 403 stainless steel as quenched and tempered. The micros...
Available to PurchasePublished: 01 January 2002
Fig. 47 Micrograph of type 403 stainless steel as quenched and tempered. The microstructure is predominantly tempered martensite, with cracking promoted by the seam. 100×; Vilella's reagent. Source: Ref 27
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Image
Two portions of a modified type 403 stainless steel steam turbine blade dam...
Available to PurchasePublished: 15 January 2021
Fig. 9 Two portions of a modified type 403 stainless steel steam turbine blade damaged by liquid impingement erosion. The portion at left was protected by a 1 mm (0.04 in.) thick shield made of rolled Stellite 6B brazed onto the leading edge of the blade; the portion at right was unprotected
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Image
Single-origin corrosion-fatigue crack in type 403 stainless steel exposed t...
Available to PurchasePublished: 15 January 2021
Fig. 22 Single-origin corrosion-fatigue crack in type 403 stainless steel exposed to steam showing rubbed origin (arrow) and beach marks. Scanning electron fractograph (secondary electron image). Original magnification: 60×
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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
... 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...
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.
Image
Micrographs of cracks after heat treatment caused by seams in the steel. (a...
Available to Purchase
in Problems Associated with Heat Treated Parts
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 5 Micrographs of cracks after heat treatment caused by seams in the steel. (a) Society of Automotive Engineers (SAE) 8630 steel as-quenched; microstructure is martensite where cracking initiated from rolling seam (b) SAE type 403 stainless steel as-quenched and tempered; microstructure
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Image
Micrographs of cracks after heat treatment caused either by sharp radii or ...
Available to Purchase
in Problems Associated with Heat Treated Parts
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
steel as-quenched and tempered; microstructure is tempered martensite with quench crack at the radius. 3% nital etch. Original magnification: 100×. (c) SAE 8630 steel as-quenched; microstructure is martensite where cracking initiated from rolling seam. (d) SAE type 403 stainless steel as-quenched
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Book Chapter
Failure of the J79 Engine Compressor Blade Due to Stall
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001757
EISBN: 978-1-62708-241-9
... is consistent with 403 stainless steel. Quantitative chemical compositions of compressor rotor blades are summarized in Table 2 for comparison with the nominal chemical composition of STS403. The measured composition seems to be in agreement with the nominal composition of STS403. Nominal and measured...
Abstract
Rotor blades in the compressor section of a J79 engine had failed. Optical, stereoscopic, microhardness testing, and SEM examinations were conducted to determine the cause. The blades were made of STS403 and were used uncoated. They were damaged over an extensive area, from the 15th through the 17th compressor stages, as were stator vanes and casing sections. The fractured surface of the 17th blade showed multiple origins along with secondary cracking and extensive propagation that preceded separation. The metallographic analysis of the microstructure suggested work hardening. Based on the results, the cause of the fractured blade was high-amplitude fatigue due to severe stall. After normal engine usage of five months, the blade fractured sending fragments throughout the combustion and turbine sections.
Book Chapter
The Role of Metallography and Fractography in the Analysis of Gun Tube Failures
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001671
EISBN: 978-1-62708-234-1
... structure with a relative hardness of 790 HK (25gf load). This sub-layer has an apparent unresolved substructure after etching. A second layer, which is occasionally reported, is a lower carbon containing austenitic layer with a hardness of 403 HK which lacks any evidence of being influenced by etching...
Abstract
Important clues about the probable cause of a gun tube explosion were obtained from a fractographic and metallographic examination of the fragments. The size, distribution, and surface markings of fragments may be used to localize the explosion and deduce its intensity. Microstructural features such as voids, adiabatic shear, and structural surface alterations also indicate the explosion intensity and further allow a comparison of the tube structure near and away from the explosion zone. These, and other metallurgical characteristics, are illustrated and discussed for cases of accidental and deliberately caused explosions of large caliber gun tubes.
Book Chapter
Overload Failure of a Crane on an Offshore Platform Related to Stress-Corrosion Cracking
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001672
EISBN: 978-1-62708-236-5
... , Metals Park, OH , pp. 403 – 410 ( 1985 ). 6. Ewalds H. L. and Wanhill R.J.H. , Fracture Mechanics , Edward Arnold , p. 173 ( 1984 ). 7. Bursle A. J. and Pugh E. N. , “An Evaluation of Current Models for the Propagation of Stress-Corrosion Cracks,” Environmental...
Abstract
Failed ferrous components were analyzed from a crane that operated on an offshore platform. The crane failed during operation and fell into the sea. The brake spring on the boom hoist was found to have fractured in four places. The spring contained a line defect (seam) that was the source of each crack. The fracture of the oil quenched and tempered (HRC 50 ASTM A229) spring was by stress-corrosion cracking after the crane fell into the sea because fatigue cannot account for the fractures observed. The crane failure was caused by an overload created by the operator catching a free-falling load.
Book Chapter
Failed Bolts From an Army Tank Recoil Mechanism
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001379
EISBN: 978-1-62708-215-0
... not independently contribute to premature failure of the bolt. Generally, the bolts from the inventory exhibited higher torque failure values (averaging 546 N m, or 403 ft . lbf) when compared to the bolts from the field (averaging 469 N m, or 346 ft . lbf). Stress Durability Testing To investigate...
Abstract
The heads of two AISI 8740 steel bolts severed while being installed into an Army tank recoil mechanism. Both broke into two pieces at the head-to-shank radius and the required torque value had not been attained nor exceeded prior to the failure. A total of 69 bolts from inventory and the field were tested by magnetic particle inspection. One inventory bolt failed because of a transverse crack near the head-to-shank radius. It was deduced that either a 100% magnetic particle inspection had not been conducted during bolt manufacturing, or the crack went undetected during the original inspection. Optical and electron microscopy of the broken bolts revealed topographies and the presence of black oxide consistent with quench cracking. The two bolts failed during installation due to the presence of pre-existing quench cracks. Recommendations to prevent future failures include: ensuring that 100% magnetic particle inspections are conducted after bolts are tempered; using dull cadmium plate or an alternative to the electrode position process, such as vacuum cadmium plate or ion-plate or ion-plated aluminum, to mitigate the potential for delayed failures due to hydrogen embrittlement or stress-corrosion cracking; ensuring that the radius at the shoulder/shank interface conforms to specifications; and replacing all existing bolts with new or reinspected inventory bolts.
Book Chapter
Analysis of Degradation and Failure Mechanisms that Develop in Hot Forging Die
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001848
EISBN: 978-1-62708-241-9
.... : Identification of failure mechanisms of H13 die on relation to the forging process—a case study of brass gas valves . Eng. Fail. Anal . 17 , 403 – 415 ( 2010 ) 10.1016/j.engfailanal.2009.08.015 6. Njeh F. , Kchaou M. , Elleuch R. , Hallouani F. : Failure modes of die used...
Abstract
A forging die in a 250-ton press producing brass valves began to show signs of fatigue after a few thousand hits. By the time it reached 30,000 hits, the die was badly damaged and was submitted for analysis along with one of the last forgings produced. The investigation included visual and macroscopic inspection, metallographic and chemical analysis, SEM imaging, optical profilometry, mechanical property testing, and EDX analysis. The die was made of chromium hot-work tool steel and the forgings were made of CuZn39Pb3 heated to an initial working temperature 700 deg C. The entire surface of the die was covered with fatigue cracks and many fillets had been plastically deformed. Several other types of damage were also observed, including areas of oxidation, corrosion pits, voids, abrasive wear, die adhesion, and thermal fatigue. Fatigue cracking was the primary cause of failure with significant contributions from the other damage mechanisms.
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
... shield of Stellite 6B; the other portion (at right, Fig. 9 ) was unprotected type 403 (modified) stainless steel. The shield, made of 1 mm (0.04 in.) thick rolled strip and brazed onto the leading edge, resisted erosion quite effectively, but the unprotected base metal did not. Fig. 9 Two...
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
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006796
EISBN: 978-1-62708-295-2
.... , Vol 47 , 2010 , p 314 – 321 10.1080/18811248.2010.9711960 11. Ikohagi T. , On Evaluation of LDI Erosion Rate Based on Fluid/Solid Coupled Simulation , Eighth Int. Conf. Flow Dynamics , 2011 , p 402 – 403 12. Li R. , Ninokata H. , and Mori M. , A Numerical...
Abstract
Erosion of a solid surface can be brought about by liquid droplet impingement (LDI), which is defined as "progressive loss of original material from a solid surface due to continued exposure to erosion by liquid droplets." In this article, the emphasis is placed on the damage mechanism of LDI erosion under the influence of a liquid film and surface roughness and on the prediction of LDI erosion. The fundamentals of LDI and processes involved in initiation of erosion are also discussed.
Book Chapter
Wear Failure of a Leaded Bronze Bearing: Correlation Between Plant Experience and Laboratory Wear Test Data
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001530
EISBN: 978-1-62708-225-9
.... Sci. Technol. , 1993 , 9 , pp. 403 – 07 . 8. Davis F.A. and Eyre T.S. : “Wear of Plain Bearing Materials With Particular Reference to Soft Phases,” Mater. Sci. Technol. , 1991 , 7 , pp. 746 – 56 . 9. Anon : Metals Handbook , Properties and Selection of Materials...
Abstract
This paper describes an investigation on the failure of a large leaded bronze bearing that supports a nine-ton roller of a plastic calendering machine. At the end of the normal service life of a good bearing, which lasted for seven years, a new bearing was installed. However the new one failed catastrophically within a few days, generating a huge amount of metallic wear debris and causing pitting on the surface of the cast iron roller. Following the failure, samples were collected from both good and failed bearings. The samples were analyzed chemically and their microstructures examined. Both samples were subjected to accelerated wear tests in a laboratory type pin-on-disk apparatus. During the tests, the bearing materials acted as pins, which were pressed against a rotating cast iron disk. The wear behaviors of both bearing materials were studied using weight loss measurement. The worn surfaces of samples and the wear debris were examined by light optical microscope, SEM, and energy-dispersive x-ray microanalyzer. It was found that the laboratory pin-on-disk wear data correlated well with the plant experience. It is suggested that the higher lead content ~18%) of the good bearing compared with 7% lead of the failed bearing helped to establish a protective transfer layer on the worn surface. This transfer layer reduced metal-to-metal contact between the bearing and the roller and resulted in a lower wear rate. The lower lead content of the failed bearing does not allow the establishment of a well-protected transfer layer and leads to rapid wear.
Book Chapter
Fracture of a Core Component in a Nuclear Reactor
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001515
EISBN: 978-1-62708-229-7
.... The CANDU Fuel Channel The fuel channels of CANDU reactors consist of a pressure tube (about 6 m long, 103 mm inside diameter and 4 mm wall thickness) made of Zr-2.5Nb, attached to the heattransport system by a mechanical joint with a 403 stainless steel end fitting, and surrounded by a thin Zircaloy-2...
Abstract
This paper describes the analysis of the failure of a Zr-2.5Nb pressure tube in a CANDU reactor. The failure sequence was established as: (1) the existence of an undetected manufacturing flaw in the form of a lamination, (2) in-service development of the flaw by oxidation of the lamination, (3) delayed hydride cracking, which extended the flaw through the wall of the tube, resulting in leakage, and (4) rupture of the tube by cold pressurization while the reactor was shut down. The comprehensive failure analysis led to a remedial action plan that permitted the reactor to be returned to full-power operation and ensured a low probability of a similar occurrence for all CANDU reactors.
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
... rainstorms. Much research has been devoted to liquid-droplet erosion, and good summaries can be found in Ref 2 and 7 . The standard blade material in steam turbines manufactured all over the world is martensitic steel containing 12 to 13% Cr (similar to types 403 and 410) and a variety of secondary...
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.
Book Chapter
Alloy 430 Ferritic Stainless Steel Welds Fail due to Stress-Corrosion Cracking in Heat-Recovery Steam Generator
Available to PurchaseSeries: 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
... , American Society for Metals , Metals Park, OH , 1973 , pp. 403 . 16. Anon. : “ Alloy 430 Time-Temperature-Transformation Phase Diagram ,” Carpenter Technology , Reading, PA . 17. Peckner D. and Bernstein I.M. : Handbook of Stainless Steel , McGraw-Hill , New York, NY , 1977...
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.
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