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Steel tube
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0091009
EISBN: 978-1-62708-235-8
..., immediately prior to heat treatment. Multiple-pass arc welds secured the carbon-steel flanges to the Ni-Cr-Mo-V alloy steel tubes. Investigation (visual inspection, metallographic analysis, and evaluation of the fabrication history and the analysis data) supported the conclusion that the tube failed...
Abstract
A thick-walled tube that was weld fabricated for use as a pressure vessel exhibited cracks. Similar cracking was apparent at the weld toes after postweld stress relief or quench-and-temper heat treatment. The cracks were not detectable by nondestructive examination after welding, immediately prior to heat treatment. Multiple-pass arc welds secured the carbon-steel flanges to the Ni-Cr-Mo-V alloy steel tubes. Investigation (visual inspection, metallographic analysis, and evaluation of the fabrication history and the analysis data) supported the conclusion that the tube failed as a result of stress-relief cracking. Very high residual stresses often result from welding thick sections of hardenable steels, even when preheating is employed. Quenched-and-tempered steels containing vanadium, as well as HSLA steels with a vanadium addition, have been shown to be susceptible to this embrittlement. Manufacturers of susceptible steels recommend use of these materials in the as-welded condition.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001626
EISBN: 978-1-62708-235-8
... Abstract A type 17-4PH stainless steel tube exhibited brown discoloration after a pickling operation. EDS analysis of the extracted substance revealed relatively high levels of iron and chromium, along with lower amounts of aluminum, silicon, sulfur, chlorine, calcium, manganese, and nickel...
Abstract
A type 17-4PH stainless steel tube exhibited brown discoloration after a pickling operation. EDS analysis of the extracted substance revealed relatively high levels of iron and chromium, along with lower amounts of aluminum, silicon, sulfur, chlorine, calcium, manganese, and nickel. The iron, chromium, and nickel are likely in the form of dissolution products from the pickling solution. FTIR analysis revealed the presence of polypropylene and poly(ethylene:propylene). The EDS results showed that the discoloration of the tube was associated with oxidation products of the tube material, as well as adherent organic residue. Analysis by FTIR of the residue revealed detectable levels of two polymeric substances, which were later determined to be construction materials of the pickling tank. It was recommended that more frequent cleaning and/or replacement of the pickling solution be put into place and another type of tank material be considered.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0091336
EISBN: 978-1-62708-234-1
... Abstract A type 304 austenitic stainless steel tube (0.008 max C, 18.00 to 20.00 Cr, 2.00 max Mn, 8.00 to 10.50 Ni) was found to be corroded. The tube was part of a piping system, not yet placed in service, that was exposed to an outdoor marine environment containing chlorides. As part...
Abstract
A type 304 austenitic stainless steel tube (0.008 max C, 18.00 to 20.00 Cr, 2.00 max Mn, 8.00 to 10.50 Ni) was found to be corroded. The tube was part of a piping system, not yet placed in service, that was exposed to an outdoor marine environment containing chlorides. As part of the assembly, a fabric bag containing palladium oxide was taped to the tube. The palladium served as a “getter.” Investigation (visual inspection and EDS analysis of corrosion debris) supported the conclusion that chlorides and palladium both contributed to corrosion in the crevice created by the tape on the tube, which was periodically exposed to water. Recommendations included taking steps to prevent water from entering and being trapped in this area of the assembly.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048309
EISBN: 978-1-62708-229-7
... Abstract A 75 mm OD x 7.4 mm wall thickness carbon steel boiler tube ruptured. A substantial degree of corrosion on the water-side surface leaving a rough area in the immediate vicinity of the rupture was revealed by visual examination. Decarburization and extensive discontinuous intergranular...
Abstract
A 75 mm OD x 7.4 mm wall thickness carbon steel boiler tube ruptured. A substantial degree of corrosion on the water-side surface leaving a rough area in the immediate vicinity of the rupture was revealed by visual examination. Decarburization and extensive discontinuous intergranular cracking was revealed by microscopic examination of a cross section through the tube wall at the fracture. It was concluded that the rupture occurred because of hydrogen damage involving the formation of methane by the reaction of dissolved hydrogen with carbon in the steel. Hydrogen was produced by the chemical reaction that corroded the internal tube surface. Steel embrittled by hydrogen can be restored only if grain boundary cracking or decarburization had not occurred but since the material embrittled in this manner, its replacement was recommended.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001110
EISBN: 978-1-62708-214-3
... Abstract A 44.5 mm (1.75 in.) diam type 321 stainless steel seamless tube in a power-generating turbine failed after 19,000 h in service. The tube was used to carry a mixture of approximately 25% steam and 75% hot air. Three fractured pieces and part of the tube containing the mating fracture...
Abstract
A 44.5 mm (1.75 in.) diam type 321 stainless steel seamless tube in a power-generating turbine failed after 19,000 h in service. The tube was used to carry a mixture of approximately 25% steam and 75% hot air. Three fractured pieces and part of the tube containing the mating fracture surface were examined. Both fractographic and metallographic features revealed that the failure was by thermal fatigue caused by the presence of biaxial thermal stresses on the inner surface of the tube. It was recommended that the steam and air be thoroughly mixed prior to entering the tube to decrease the temperature fluctuations of the inner surface.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001811
EISBN: 978-1-62708-241-9
... Abstract A deformed steel tube was received for failure analysis after buckling during a heat-treat operation. The tube was subjected to various metallurgical tests as well as nondestructive testing to confirm the presence of residual stresses. The microstructure of the tube was found...
Abstract
A deformed steel tube was received for failure analysis after buckling during a heat-treat operation. The tube was subjected to various metallurgical tests as well as nondestructive testing to confirm the presence of residual stresses. The microstructure of the tube was found to be homogenous and had no banded structure. However, x-ray diffraction analysis confirmed the presence of up to 6% retained austenite which likely caused the tube to buckle during the 910 °C heat treating procedure.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048331
EISBN: 978-1-62708-229-7
... Abstract The top tube of a horizontal superheater bank in the reheat furnace of a steam generator ruptured after seven years in service. The rupture was found to have occurred in the ferritic steel tubing (2.25Cr-1Mo steel (ASME SA-213, grade T-22)) near the joint where it was welded...
Abstract
The top tube of a horizontal superheater bank in the reheat furnace of a steam generator ruptured after seven years in service. The rupture was found to have occurred in the ferritic steel tubing (2.25Cr-1Mo steel (ASME SA-213, grade T-22)) near the joint where it was welded to austenitic stainless steel tubing (type 321 stainless steel (ASME SA-213, grade TP321H)). The surface temperature of the tube was found to be higher than operating temperature in use earlier. The ferritic steel portion of the tube was found to be longitudinally split and heavily corroded in the region of the rupture. A red and white deposit was found on the sides and bottom of the tube in the rupture area. The deposit was produced by attack of the steel by the alkali acid sulfate and had thinned the tube wall. It was concluded that rupture of the tube had occurred due to thinning of the wall by coal-ash corrosion. The thinned tubes were reinforced by pad welding. Type 304 stainless steel shields were welded to the stainless steel portions of the top reheater tubes and were held in place about the chromium-molybdenum steel portions of the tubes by steel bands.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001247
EISBN: 978-1-62708-228-0
... Abstract Three samples from a ruptured 316 stainless steel tube were examined. The tube, 114 mm OD, wall thickness 8.00 mm, with 13 mm thick 321 stainless steel fins welded to the outer surface of the tube, was part of a heater through which sour gas, containing methane plus H2S and CO, passed...
Abstract
Three samples from a ruptured 316 stainless steel tube were examined. The tube, 114 mm OD, wall thickness 8.00 mm, with 13 mm thick 321 stainless steel fins welded to the outer surface of the tube, was part of a heater through which sour gas, containing methane plus H2S and CO, passed at 1150 psig. The sour gas was heated to 600 deg F by burners playing on the outside of the tube burning “sweet” gas plus air. The inner and outer surfaces of all samples showed evidence of corrosive attack. Electron probe microanalysis showed the corrosion products contained sulfur with iron, together with nickel to a lesser extent. Local thinning, cavitation, and ductile deformation markings associated with the unmatched sample taken from the center of the fire showed the tube ruptured as a result of overheating. Overheating while the temperature recorder was off the chart caused severe loss of tube strength, resulting in ductile rupture. The minimum overheating temperature could be deduced at around 1200 deg F due to the presence of a eutectic observed metallographically within the surface corrosion products.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001345
EISBN: 978-1-62708-215-0
... Abstract A cold-formed Grade TP 304 stainless steel swaged region of a reheater tube in service for about 8000 hours cracked because of sulfur-induced stress-corrosion cracking (SCC). Cracking initiated from the external surface and a high sulfur content was detected in the outer diameter...
Abstract
A cold-formed Grade TP 304 stainless steel swaged region of a reheater tube in service for about 8000 hours cracked because of sulfur-induced stress-corrosion cracking (SCC). Cracking initiated from the external surface and a high sulfur content was detected in the outer diameter and crack deposits. Comparison of the microstructure and hardness of the swaged region and unswaged Grade TP 304 stainless steel tube metal indicated that the swaged section was not annealed to reduce the effects of cold working. The high hardness created during swaging increased the stainless steel's susceptibility to sulfur-induced SCC. Because SCC requires water to be present, cracking most likely occurred during downtime or startups. To prevent future failures, the boiler should be kept dry during downtime to avoid formation of sulfur acids, and the swaged sections of the tubes should be heat treated after swaging to reduce or eliminate strain hardening of the metal.
Image
Published: 01 January 2002
Fig. 4 Fracture of a steel tube. (a) Fracture surface at approximately actual size, showing point of crack initiation (at arrow), chevron and fanlike marks, and development of shear lips. (b) Fracture-origin area at 5×; note that fracture nuclei differ in texture from the main fracture surface.
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Image
Published: 01 January 2002
Fig. 34 AISI 1025 steel tube post for a carrier vehicle. The post failed in fatigue because of improper design and choice of flange metal. Dimensions given in inches
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Published: 01 January 2002
Fig. 3 A6 tool steel tube-bending-machine shaft that failed by fatigue fracture. Section A-A: Original and improved designs for fillet in failure region. Dimensions are in inches. View B: Fracture surface showing regions of fatigue-crack propagation and final fracture
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Image
Published: 01 January 2002
Fig. 25 Carbon-molybdenum steel tube that ruptured in a brittle manner after 13 years of service, because of graphitization at weld HAZs. (a) View of tube showing dimensions, locations of welds, and rupture. (b) Macrograph showing graphitization along edges of a weld HAZ (A); this was typical
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Published: 01 January 2002
Fig. 1 Pitted inside-diameter surface of AISI type 410 stainless steel tube. (a) Typical example of pitting. Approximately 2 1 2 ×. (b) Enlargement of pit shown in (a). Approximately 50×
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Published: 01 January 2002
Fig. 8 Rimmed steel tube that failed by brittle fracture after being strain aged by cold swaging.
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Published: 01 January 2002
Fig. 34 Hot cracking that developed in a stainless steel tube weld. 10% oxalic acid electrolytic etch. 30×
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Published: 01 January 2002
Fig. 25 Austenitic stainless steel tube that was corroded where a fabric bag was taped to it. Courtesy of M.D. Chaudhari, Columbus Metallurgical Service
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Published: 01 January 2002
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in Unidirectional-Bending Fatigue Failure of an A6 Tool Steel Shaft
> ASM Failure Analysis Case Histories: Machine Tools and Manufacturing Equipment
Published: 01 June 2019
Fig. 1 A6 tool steel tube-bending-machine shaft that failed by fatigue fracture. Section A-A: Original and improved designs for fillet in failure region. Dimensions are in inches. View B: Fracture surface showing regions of fatigue-crack propagation and final fracture
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in Corrosion-Fatigue Failure of Finned Stainless Steel Economizer Tubes Due to Differential Thermal Expansion
> ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment
Published: 01 June 2019
Fig. 1 Section of stainless steel tube/fin assembly removed from economizer. Note the weld geometry and fin weld locations.
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