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Diffusers
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001679
EISBN: 978-1-62708-229-7
... Abstract Several mercury diffusion pump stages in the Tritium Purification process at the Savannah River Site (SRS) have been removed from service for scheduled preventive maintenance. These stages have been examined to determine if failure has occurred. Evidence of fatigue around the flange...
Abstract
Several mercury diffusion pump stages in the Tritium Purification process at the Savannah River Site (SRS) have been removed from service for scheduled preventive maintenance. These stages have been examined to determine if failure has occurred. Evidence of fatigue around the flange portion of the pump has been seen. In addition, erosion and cavitation inside the throat of the venturi tube and corrosion on the other surface of the venturi tube has been observed. Several measures are being examined in an attempt to improve the performance of these pumps. These measures, as well as the noted observations, are described. Six stages [two machined (MP) and four electron beam (EB) welded] from the mercury diffusion pumps operating in the Tritium Purification process at SRS have been analyzed to determine their condition after nine months of usage. Several cracks were found around the necked region of the two MP stages. The EB welded stages, however, seemed to perform better in service; only two of four stages showed cracking. The cracking is caused by fatigue that has been enhanced by high stresses and tritium in the flange area. The EB welded stage appears to be a step in the right direction. Since the EB weld is a shrink fit, the surface is in compression, thereby eliminating crack propagation. In addition, shot peening has been employed to produce a compressive material surface since fatigue usually originates at the surface. Pitting was observed down the throat of the venturi. This pitting was caused by cavitation and erosion along the length of the venturi tube. Corrosion and pitting was seen on the exterior walls of the diffuser tubes. Stress-corrosion cracks were observed emanating from these corrosion pits. The corrosion likely occurred from the chloride ions present in the process cooling water. Shot peening is now being used in an attempt to place the outside of the diffuser tube in compression to eliminate the stress-corrosion cracking.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001304
EISBN: 978-1-62708-215-0
... Abstract An exhaust diffuser assembly failed prematurely in service. The failure occurred near the intake end of the assembly and involved fracture in the diffuser cone (Corten), diffuser in take flange (type 310 stainless steel), diffuser exit flange (type 405 stainless steel), expansion...
Abstract
An exhaust diffuser assembly failed prematurely in service. The failure occurred near the intake end of the assembly and involved fracture in the diffuser cone (Corten), diffuser in take flange (type 310 stainless steel), diffuser exit flange (type 405 stainless steel), expansion bellows (Inconel 600), and bellows intake flange (Corten). Individual segments of the failed subassemblies were examined using various methods. The analysis indicated that the weld joint in the diffuser intake flange (type 310 stainless steel to Corten steel) contained diffusion-zone solidification cracks. The joints had been produced using the mechanized gas-metal arc welding process. Cracking was attributed to improper control of welding parameters, and failure was attributed to weld defects.
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Published: 01 January 2002
Fig. 14 Fracture surface diffuse lighting. (a) Dual-side incandescent diffuse copystand lighting setup. (b) Resulting diffuse lighting photograph of a fatigue fracture
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 87 Biaxial stress ratios that permit no necking, diffuse necking, and local necking. Source: Ref 32
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 25 Local and diffuse necking in copper and in 200 nickel. Width-to-thickness ratio ∼24:1. Note that fracture initiation has occurred in the local necks at the edges of the specimens.
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 26 Diffuse and localized necks in an 1100 aluminum sheet tensile specimen. Source: Ref 51
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 1 Exhaust diffuser assembly. Arrow indicates direction of airflow.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 2 Diffuser cone with intake side up. Note the zigzag fracture path along intake end (large arrow) and separation (small arrows) along exit side.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 3 Fracture edge of diffuser cone near exit side, showing abrasions across weld and blisters (arrows) in diffuser cone.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 5 Representative transverse sections of diffuser intake subassembly. (a) Fracture through fusion boundary with type 310 stainless steel. (b) Fracture through welds. (c) Fracture through Corten.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 6 Transverse section of weld between intake flange (left) and diffuser cone (right). Large arrow indicates cracking near fusion boundary with type 310 stainless steel. Small arrows indicate fragments of Corten steel in fusion zone.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 8 Representative transverse sections of diffuser exit subassembly (a) Fracture in Corten. (b) Fracture in type 405 stainless steel adjacent to the weld.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 9 Fracture edge of exit diffuser flange of type 405 stainless steel, showing cracking (small arrow) and shear-type plastic deformation of grains (large arrows).
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 10 Fracture surface of diffuser cone near exit end, showing ductile dimples in type 405 stainless steel.
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in Failure Analysis of an Exhaust Diffuser Assembly
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 11 Fracture surface of diffuser cone near intake end, showing laminations and microcracks in Corten steel.
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Published: 15 May 2022
Fig. 4 Temperature dependence of diffusivity ( D ) for unidirectional T300/924 carbon/epoxy immersed in deionized water
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in Failure Analysis of Gas Turbine Engine Fuel Nozzle Heat Shields
> ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions
Published: 01 June 2019
Fig. 2 Fuel Nozzle/Heat Shield Assembly Mounting Location in Diffuser Case
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Published: 15 January 2021
Fig. 12 Wavelength-dispersive spectrometer (WDS) analysis results showing diffusion of phosphorus from the outer surface into the substrate material on an alloy steel fastener
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 25 Local diffuse necking in copper and in Monel 400. Width-to-thickness ratio, ~24:1. Note that fracture initiation occurred in the local necks at the edges of the specimens.
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 26 Diffuse localized necks in an 1100 aluminum alloy sheet tensile specimen. Source: Ref 52
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