Dezincification is a particular form of corrosive attack which may occur in a variety of environments and to which some brasses are susceptible. It is favored by waters having a high oxygen, carbon dioxide, or chloride content, and is accelerated by elevated temperatures and low water velocities. In the present study, steam turbine condenser tubes had to be renewed after 25 years of service. The tubes were nominally of 70:30 brass. The appearance of a typically corroded one showed uniform dezincification attack on the bore, extending from one-half to two-thirds through the tube wall thickness.

A welded joint between lengths of 4 in. OD x 13 SWG copper pipe which formed part of a cold-water main failed by cracking over one-third of the circumference. Microscopic examination of the filler metal showed that it had a structure corresponding to a brass of the 60:40 type commonly used for bronze welding. Failure resulted from dezincification of the joint material from the internal side of the tube. Also, a selective attack on the beta phase had occurred. It was evident that the loss in mechanical strength arising from the corrosion had resulted in the development of cracking in service. The filler metal used was not resistant to the conditions to which it was exposed. Copper welding rods as per BS 1077 or a Cu-Ag-P brazing alloy as recommended in BS 699, would have been preferable.

A brass elbow that formed one termination of a steam heating coil failed adjacent to the brazed connection after ten years of service. Chemical analysis showed that the elbow was made from a 60-40 CuZn brass containing 3% lead and 1% tin, a typical alloy used for the manufacture of components by the hot stamping process. Microscopic examination indicated failure from dezincification. The fact that the screwed end was not affected indicated that the trouble was not caused by the condensate, which flowed through the elbow, but originated from the water heated in the vessel. The helical mode of the cracking was probably due to the torsional stresses which would be imposed on the elbow by thermally induced movements of the coil in service.

A 12.7 mm (0.5 in.) diam tube was removed from a potable water supply due to leaks. The tube wall thickness was 0.711 mm (0.028 in.) with a thin layer of chromium plate on the OD surface. The tube had been in service for approximately 33 years. Investigation (visual inspection, EDS deposit analysis, metallurgical examination, and unetched magnified images) supported the conclusion that failure occurred due to porous material typical of plug-type dezincification initiating from the inside surface. Where the dezincification had progressed through the tube wall, the chromium plate had exfoliated from the base material and cracked. Recommendations included replacing the piping with a more corrosion-resistant material such as red brass (UNS C23000), inhibited Admiralty brass (UNS C44300), or arsenical aluminum brass (UNS C68700).

This article provides a background of friction-bearing failures due to overheating. The failures of locomotive axles caused by overheated traction-motor support bearings are discussed. The article also describes liquid-metal embrittlement (LME) in steel. It examines the results of various axle studies, with illustrations and concludes with information on the simulation of the LME mechanism.

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.

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.