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SEM/EDS analysis
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in Analysis of Center Burst During Hot Forging
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 9 EDS analysis and corresponding SEM micrographs of different foreign particles observed on the fracture surface of the forging near the defect
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in Analysis of Center Burst During Hot Forging
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
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Published: 01 December 1992
Fig. 4 Standardless, semiquantitative SEM/EDS element analysis of the failed carrier shaft material revealed a carbon steel composition. No contaminants were present on the fracture surface. Element Precision, wt% at.% 2σ K -Ratio Silicon 0.41 0.82 0.12 0.0015
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Published: 01 December 1992
Fig. 5 Standardless, semiquantitative SEM/EDS element analysis of the weld material revealed a type 300 stainless steel composition. Element Precision, wt.% at.% 2σ K -Ratio Silicon 1.35 2.63 0.17 0.0051 Chromium 17.84 18.72 0.52 0.2143 Iron 74.56 72.84
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Published: 01 December 2019
Fig. 6 ( a ) SEM image of coke in inner surface. ( b ) EDS analysis of ( a ). ( c ) SEM image of coke in outer surface. ( d ) EDS analysis of ( c )
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in Metallurgical Failure Analysis of Cracks in a Compressor Turbine Impeller
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 2 Standardless semi-quantitative SEM/EDS element analysis data and graph of typical corrosion residue present in some of the cracks in the eye of the second-stage impeller. The high sodium content was believed to be the corrosion component for the stress-corrosion cracks. Element
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in Metallurgical Failure Analysis of Cracks in a Compressor Turbine Impeller
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 3 Standardless semi-quantitative SEM/EDS element analysis data and graph of a crack fracture surface. Base metal elements revealed that the impeller material was an AISI 4300 alloy steel. Element wt% at.% Silicon 0.27 0.53 Chromium 1.10 1.18 Manganese 0.88
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001589
EISBN: 978-1-62708-235-8
... or particles during the plating. The possible sources of fibers were identified. The SEM/EDS analysis of fibers collected from the air duct filters correlated very well with the defect shape and the EDS profile collected from under the defect site. It appears that the fibers from air duct filters directly...
Abstract
The paper discusses the analysis of a coating defect on a high phosphorus electroless nickel (Ni-11 wt. % P) deposit plated on an aluminum alloy substrate. Preliminary investigations had indicated that the elongated defects were possibly caused by the entrapment of long fibers or particles during the plating. The possible sources of fibers were identified. The SEM/EDS analysis of fibers collected from the air duct filters correlated very well with the defect shape and the EDS profile collected from under the defect site. It appears that the fibers from air duct filters directly above the plating line were blown into the plating tank and getting co-deposited. The paper describes the step-by-step analysis of the defect that led to successful identification of the root cause of the defect.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001770
EISBN: 978-1-62708-241-9
..., the tank began leaking along the weld bead, triggering a full-scale investigation; spectroscopy, optical and scanning electron microscopy, fractography, SEM-EDS analysis, and microhardness, tensile, and impact testing. The results revealed transgranular cracks in the HAZ and base plate, likely initiated...
Abstract
A storage tank had been in service at a petrochemical plant for 13 years when inspectors discovered cracks adjacent to weld joints and in the base plate near the foundation. The tank was made from AISI 304 stainless steel and held styrene monomer, a derivative of benzene. The cracks were subsequently welded over with 308 stainless steel filler wire and the base plate was replaced with new material. Soon after, the tank began leaking along the weld bead, triggering a full-scale investigation; spectroscopy, optical and scanning electron microscopy, fractography, SEM-EDS analysis, and microhardness, tensile, and impact testing. The results revealed transgranular cracks in the HAZ and base plate, likely initiated by stresses developed during welding and the presence of chloride from seawater used in the plant. It was also found that the repair weld was improperly done, nor did it include a postweld heat treatment to remove weld sensitization and minimize residual stresses.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001843
EISBN: 978-1-62708-241-9
... to determine what caused the change. The order stated that the connectors were to be coated with a layer of tin-bismuth (2% Bi) to guard against tin pest, a type of degradation that occurs at low temperatures. Based on the results of the investigation, which included SEM/EDS analysis, inductively coupled...
Abstract
The operator of an electric transit system purchased a large number of tin-plated copper connectors, putting some in service and others in reserve. Later, when some of the reserve connectors were inspected, the metal surfaces were covered with spots consisting of an ash-like powder and the plating material had separated from the substrate in many areas. Several connectors, including some that had been in service, were examined to determine what caused the change. The order stated that the connectors were to be coated with a layer of tin-bismuth (2% Bi) to guard against tin pest, a type of degradation that occurs at low temperatures. Based on the results of the investigation, which included SEM/EDS analysis, inductively coupled plasma spectroscopy, and x-ray diffraction, the metal surfaces contained less than 0.1% Bi and thus were not adequately protected against tin pest, which was confirmed as the failure mechanism in the investigation.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001328
EISBN: 978-1-62708-215-0
... the specifications of these filler metals. SEM/EDS analysis showed base metal grain boundary precipitates to he primarily chromium carbides, but some titanium carbides were also observed. Most apparent stringer compounds were titanium carbides (and titanium cyanonitrides), but chromium carbides were also...
Abstract
During 5.7 years of service, dye penetrant inspection of Inconel 800H pigtail connections regularly showed cracks at weld toes. Weld repairs were not able to prevent reoccurrence but often aggravated the condition. Samples containing small, but detectable, reducer-to-pigtail cracks showed intergranular cracks originating at weld toes and filled with oxidation product, which precluded determination of the cracking mechanism. All weldments exhibited high degrees of secondary precipitates, with original fabrication welds exhibiting higher apparent levels than repair welds. SEM/EDS analysis showed base metal grain boundary precipitates to be primarily chromium carbides, but some titanium carbides were also observed. Failure was believed to result from the synergism of thermally driven tube distortion, which resulted in over-stress, and from the intergranular oxidation products and intergranular carbides which contributed to cracking. It was recommended that stresses be reduced and /or that materials and components be changed. Refinements in welding procedures and implementation of preweld/postweld heat treatments were recommended also.
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in Pitting Corrosion of Steel Tubes in an Air Preheater
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 12 SEMs with EDS analysis showing the severe corrosion at ID of the Stage 3 tube. (a) Note the irregular shape of the corrosion products and loose/porous scale. (b) Note the embedded ash/silica particles.
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in Pitting Corrosion of Steel Tubes in an Air Preheater
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 13 SEMs with EDS analysis showing the severe corrosion at ID of the Stage 3 tube. (a) Note the porous nature of the corrosion products Cl (bright) and Si (dark). (b) Note the silica particles (smooth area).
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Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001784
EISBN: 978-1-62708-241-9
... of narrow end of the failed wench socket Fig. 7 SEM micrograph of the same site as shown in Fig. 4 at lower magnification Abstract A 13/16-in. hex socket failed while in use. Analysis (hardness testing, optical and scanning electron microscopy, and EDS) revealed that the socket was made...
Abstract
A 13/16-in. hex socket failed while in use. Analysis (hardness testing, optical and scanning electron microscopy, and EDS) revealed that the socket was made of low carbon steel formed in a powder metallurgy process. A number of flaws were found including nonuniform wall thickness, poor geometric design with sharp corners as stress raisers, and incomplete sintering evidenced by unsintered particles. These were determined to be the primary cause of failure, although inclusions on the fracture surface containing S and Al may have played a role as well.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001066
EISBN: 978-1-62708-214-3
... and contained multiple branches ( Fig. 5 ), a form commonly associated with stress-corrosion cracking (SCC). Qualitative chemical analysis of the spool piece material was performed using SEM and energy-dispersive X-ray spectroscopy (EDS). Results indicated that the alloy composition was consistent with low...
Abstract
A flanged 100 mm (4 in.) diam low-carbon steel spool piece lined with Teflon was removed from a sulfuric acid denitrification system after cracks were observed in the painted coating. Visual and microstructural examination along with SEM fractography revealed scaled iron oxides on all opened crack surfaces. The surfaces had a faceted morphology, indicating intergranular fracture. Cracks originated at the interface between the tube and the Teflon liner Corrosion products were found caked into the intergranular region between the liner and the spool. The portion of the liner that had been exposed to the process stream was discolored. Failure of the spool was attributed to stress-corrosion cracking promoted by the presence of nitrates. Nitric acid contaminant in the sulfuric acid stream had diffused through the liner and accumulated in the annular space. Use of a liner that is more impermeable to the diffusion of ionic species was recommended.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001344
EISBN: 978-1-62708-215-0
...SEM-EDS analysis of a fracture surface Table 2 SEM-EDS analysis of a fracture surface Element Composition, % Iron 67.5 Chromium 17.0 Sodium 6.0 Nickel 6.0 Silicon 2.0 Calcium 1.0 Aluminum <0.5 Sulfur <0.5 Chemical analysis of the stainless...
Abstract
Several 304H stainless steel superheater tubes fractured in stressed areas within hours of a severe caustic upset in the boiler feedwater system. Tests performed on a longitudinal weld joint, which connected two adjacent tubes in the tertiary superheater bank, confirmed caustic-induced stress-corrosion cracking, promoted by the presence of residual welding stresses. Improved maintenance of check valves and routine inspection of critical monitoring systems (conductivity alarms, sodium analyzers, etc.) were recommended to help avoid future occurrences of severe boiler feedwater contamination. Additional recommendations were to eliminate these short longitudinal weld joints by using a bracket assembly joint between the tubes, use a post-weld heat treatment to relieve residual welding stress or select a more stress-corrosion cracking resistant alloy for this particular application.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001367
EISBN: 978-1-62708-215-0
... Standardless semi-quantitative SEM/EDS element analysis data and graph of typical corrosion residue present in some of the cracks in the eye of the second-stage impeller. The high sodium content was believed to be the corrosion component for the stress-corrosion cracks. Element wt...
Abstract
Cracking was discovered in an in-service, second-stage turbine impeller during a downtime inspection. The fabricated 4300 series low-alloy steel impeller was used in a compressor in an industrial petrochemical plant. It was also reported that a process upset had allowed a 10% NaOH solution to be ingested by the unit. Routine magnetic particle inspection revealed numerous cracks in the hub area and vane tips of the second-stage impeller Additionally, the outside surface of the backing plate showed a cyclic pattern of cracks. An overview of a conventional, systematic metallurgical approach to failure analysis to confirm that the cracking was caused by a caustic stress-corrosion cracking mechanism is presented.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001836
EISBN: 978-1-62708-241-9
... and Forming of Tubing , Metalworking: Sheet Forming , Vol 14B , ASM Handbook , Semiatin S.L. , Ed., ASM International , 2006 , p 461 – 471 . 10.31399/asm.hb.v14b.a0005135 Chemical Composition Metallographic Analysis SEM–EDS Analysis Introduction Conclusions Final...
Abstract
An investigation was conducted to determine why 16 out of 139 pipe bends cracked during hot induction bending. The pipe conformed to API 5L X65 PSL2 line pipe standards and measured 1016 mm (40 in.) in diam with a wall thickness of 18.5 mm. A metallurgical cross section was removed along a crack on the extrados to document the crack morphology using optical microscopy. In addition to cracking, golden-yellow streaks were visible at the extrados, and the composition was examined using scanning electron microscopy with energy dispersive spectroscopy. Based on the results, investigators concluded the pipe was contaminated with copper at the mill were it was produced.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001771
EISBN: 978-1-62708-241-9
... carbide in grain boundary. ( b ) SEM image reveal grain boundary morphology. ( c , d ) the EDS analysis of chemical composition of carbide and matrix marked 1 and 2 on ( b ), respectively Fig. 4 ( a ) Optical microstructure shows continuous grain boundary and blocky carbide precipitated...
Abstract
Radiant tubes that failed prematurely in an ethylene cracking furnace were analyzed to determine the cause of their early demise. The tubes were made from austenitic heat-resistant steel and cracked along their longitudinal axis. New and used tubes were compared using scanning electron microscopy, energy dispersive x-ray spectrometry, and mechanical property testing. This provided critical information and revealed that improper coking and decoking had removed the protective oxide layer (Cr 2 O 3 ) that normally prevents coke deposits from forming on exposed surfaces. Without this layer, coke readily accumulates on the surface of the tubes, fueling carbon diffusion into the metal and a corresponding degradation in microstructure and loss of ductility at high temperatures.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0090994
EISBN: 978-1-62708-225-9
... strength range was 1689 to 1793 MPa (245 to 260 ksi). The finished springs were to be shot peened for greater fatigue resistance. Investigation (visual inspection, 3x images, 2% nital etched 148x SEM images, chemical analysis, hardness testing, and EDS analysis) supported the conclusion that the springs...
Abstract
Two large tension springs fractured during installation. The springs were manufactured from a grade 9254 chromium-silicon steel spring wire. The associated material specification allows wire in the cold-drawn or oil-tempered (quenched-and-tempered) condition. The specified wire tensile strength range was 1689 to 1793 MPa (245 to 260 ksi). The finished springs were to be shot peened for greater fatigue resistance. Investigation (visual inspection, 3x images, 2% nital etched 148x SEM images, chemical analysis, hardness testing, and EDS analysis) supported the conclusion that the springs failed during installation due to the presence of preexisting defects. Crack surfaces were found to be corroded and phosphate coated, indicating that the cracks occurred during manufacture. Installation, which presumably entailed some axial extension, resulted in ductile overload failure at the crack sites. Recommendations included evaluating the manufacturing steps to identify the process(es) wherein the cracking was likely occurring. It was further recommended that a suitable nondestructive method such as magnetic particle inspection be implemented.
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