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Book Chapter
Heat Exchanger Corrosion in a Chlorinated Solvent Incinerator
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001046
EISBN: 978-1-62708-214-3
... gases to shunt across the preheater/exchanger. Metallographic examination of the plates showed that accelerated internal oxidation had been the cause of failure. Corrosion racks of candidate alloys (types 304, 309, and 316 stainless steels, Inconel 600, Inconel 625, Incoloy 800, Incoloy 825, and Inco...
Abstract
The thin plates within a type 309 stainless steel chlorinated solvent combustion preheater/heat exchanger designed to process fumes from a solvent coating process showed severe corrosion within 6 months of service. Within a year corrosion had produced holes in the plates, allowing gases to shunt across the preheater/exchanger. Metallographic examination of the plates showed that accelerated internal oxidation had been the cause of failure. Corrosion racks of candidate alloys (types 304, 309, and 316 stainless steels, Inconel 600, Inconel 625, Incoloy 800, Incoloy 825, and Inco alloy C-276) were placed directly in the hot gas stream, containing HCl and Cl2, for in situ testing. Results of this investigation showed that nickel-chromium corrosion-resistant alloys, such as Inconel 600, Inconel 625, and Inco alloy C-276, performed well in this environment. Laboratory testing of the same alloys, along with Inconel alloys 601, 617, and 690 and stainless steel type 347 was also conducted in a simulated waste incinerator nitrogen atmosphere containing 10% Co2, 9% O2, 4% HCl, 130 ppm HBr and 100 ppm SO2 at 595, 705, 815, and 925 deg C (1100, 1300,1500, and 1700 deg F). The tests confirmed the suitability of the nickel-chromium alloys for such an environment. Inconel 625 was selected for fabrication of a new preheater/exchanger.
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Torsion fracture in an aluminum-silicon alloy (alloy 319-T5). Classic britt...
Available to Purchase
in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 52 Torsion fracture in an aluminum-silicon alloy (alloy 319-T5). Classic brittle torsion fracture on a plane at 45° to the axis of the cylinder. Hardness, 38 HRB; tensile strength, 179 MPa (26 ksi); total elongation, 0.5%. Source: Ref 42
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Macroscale brittle torsion fracture in an aluminum-silicon alloy (alloy A35...
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 53 Macroscale brittle torsion fracture in an aluminum-silicon alloy (alloy A356 sand casting). Hardness, 38 HRB; tensile strength, 214 MPa (31 ksi); total elongation, 4%. Source: Ref 42
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Torsion fracture in an aluminum-silicon alloy (alloy 319-T5). Classic britt...
Available to Purchase
in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 52 Torsion fracture in an aluminum-silicon alloy (alloy 319-T5). Classic brittle torsion fracture on a plane at 45° to the axis of the cylinder. Hardness, 38 HRB; tensile strength, 179 MPa (26 ksi); total elongation, 0.5%. Source: Ref 43
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Image
Macroscale brittle torsion fracture in an aluminum-silicon alloy (alloy A35...
Available to Purchase
in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 53 Macroscale brittle torsion fracture in an aluminum-silicon alloy (alloy A356 sand casting). Hardness, 38 HRB; tensile strength, 214 MPa (31 ksi); total elongation, 4%. Source: Ref 43
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Perforation of alloy 690 incinerator liner near alloy 160 patch, showing th...
Available to PurchasePublished: 15 January 2021
Fig. 3 Perforation of alloy 690 incinerator liner near alloy 160 patch, showing that the original 6.35 mm (0.250 in.) wall thickness was reduced to approximately 1.27 mm (0.050 in.) or less in the general area of failure. Courtesy of U.S. Navy
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Comparison of wear surfaces for low-alloy steel specimens worn in (a) flow-...
Available to PurchasePublished: 01 January 2002
Fig. 5 Comparison of wear surfaces for low-alloy steel specimens worn in (a) flow-through and (b) recycled slurry tests for 1 h and 1.67 h, respectively. Source: Ref 13
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Wear surface by cavitation of copper-base alloy in a lubricated gearbox. Co...
Available to PurchasePublished: 01 January 2002
Fig. 2 Wear surface by cavitation of copper-base alloy in a lubricated gearbox. Courtesy of CETIM
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Aluminum alloy 6063-T6 extension-ladder side-rail extrusion that failed by ...
Available to PurchasePublished: 01 January 2002
Fig. 3 Aluminum alloy 6063-T6 extension-ladder side-rail extrusion that failed by plastic deformation and subsequent buckling. (a) Configuration and dimensions (given in inches). (b) Relation of maximum applied load to the section thickness of the flanges and web of the side-rail extrusion.
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Micrograph of a section through a copper-lead alloy bearing that failed by ...
Available to PurchasePublished: 01 January 2002
Fig. 7 Micrograph of a section through a copper-lead alloy bearing that failed by deleading. Light area at the upper surface is the copper matrix that remained after the alloy was depleted of lead. As-polished. 100×
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Low-alloy steel roller bearing from an improperly grounded electric motor t...
Available to PurchasePublished: 01 January 2002
Fig. 7 Low-alloy steel roller bearing from an improperly grounded electric motor that was pitted and etched by electrolytic action of stray electric currents in the presence of moisture.
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Aluminum alloy lifting sling that fractured because of improper welding of ...
Available to PurchasePublished: 01 January 2002
Fig. 21 Aluminum alloy lifting sling that fractured because of improper welding of the cross member to the sling body. (a) Configuration and dimensions (given in inches). (b) Fracture surfaces of the sling body (top) and the cross member (bottom). (c) Enlarged view of a fracture surface
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Cracked HL22-8 aluminum alloy 7075-T6 fasteners. (a) and (b) Typical cracke...
Available to PurchasePublished: 01 January 2002
Fig. 3 Cracked HL22-8 aluminum alloy 7075-T6 fasteners. (a) and (b) Typical cracked fastener head. (c) Typical head cracks produced by installing fasteners in misaligned holes during testing
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Die-cast zinc alloy nuts from a water tap. (a) Nut for the cold-water tap t...
Available to PurchasePublished: 01 January 2002
Fig. 11 Die-cast zinc alloy nuts from a water tap. (a) Nut for the cold-water tap that failed by SCC. (b) Mating nut for the hot-water top that shows only isolated areas of corrosion. (c) Unetched section showing metal in the cold-water tap after corrosion testing. 600×
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Cadmium-plated alloy steel self-retaining bolts that fractured because of h...
Available to PurchasePublished: 01 January 2002
Fig. 13 Cadmium-plated alloy steel self-retaining bolts that fractured because of hydrogen damage. (a) Fractured and unused intact bolt. (b) Fractured bolt; brittle fracture surface is indicated by A and B. (c) and (d) Electron fractographs of surfaces A and B, respectively, showing brittle
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Cadmium-plated AISI 8740 alloy steel fasteners that failed by hydrogen embr...
Available to PurchasePublished: 01 January 2002
Fig. 14 Cadmium-plated AISI 8740 alloy steel fasteners that failed by hydrogen embrittlement. See also Fig. 15 .
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Alcan aluminum alloy B54S-O rivet that failed by stress corrosion after bei...
Available to PurchasePublished: 01 January 2002
Fig. 20 Alcan aluminum alloy B54S-O rivet that failed by stress corrosion after being heated for 7 days at 100 °C (212 °F). (a) Section through rivet showing shape of fracture surface. 5×. (b) Micrograph showing an intergranular fracture path. 450×
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AISI 4150 alloy steel chuck jaw that broke because of the presence of a bri...
Available to PurchasePublished: 01 January 2002
Fig. 27(a) AISI 4150 alloy steel chuck jaw that broke because of the presence of a brittle white-etching nitride surface layer. The part was hardened and tempered before nitriding. A micrograph of a broken tooth (arrows) of this chuck jaw is shown in Fig. 27(b) .
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Copper alloy C70600 tube from a hydraulic-oil cooler. The cooler failed fro...
Available to PurchasePublished: 01 January 2002
Fig. 5 Copper alloy C70600 tube from a hydraulic-oil cooler. The cooler failed from crevice corrosion caused by dirt particles in river water that was used as a coolant. (a) Inner surface of hydraulic-oil cooler tube containing a hole (arrow A) and nodules (one of which is indicated by arrow B
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Copper alloy C26000 steam-turbine condenser tube that failed by dezincifica...
Available to PurchasePublished: 01 January 2002
Fig. 6 Copper alloy C26000 steam-turbine condenser tube that failed by dezincification. (a) Section through condenser tube showing dezincification of inner surface. 3 1 2 ×. (b) Etched specimen from the tube showing corroded porous region at the top and unaffected region below. 100×
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