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in Failure of Nickel-Aluminum-Bronze Hydraulic Couplings, with Comments on General Procedures for Failure Analysis
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
Fig. 13 TEM replica of a fracture surface of WC-3Co cemented carbide exhibiting Wallner lines (arrowed) 8
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c0046998
EISBN: 978-1-62708-232-7
... with mixed acids, metallographic examination, and chemical analysis) supported the conclusions that the premature failure of the tube by perforation at the hearth level resulted from (1) corrosion caused by sulfur contamination from the refractory cement in contact with the tube and (2) severe local...
Abstract
One of 14 vertical radiant tubes (RA 333 alloy) in a heat-treating furnace failed when a hole about 5 x 12.5 cm (2 x 5 in.) corroded completely through the tube wall. The tube measured 183 cm (72 in.) in length and 8.9 cm (3 in.) in OD and had a wall thickness of about 3 mm (0.120 in.). Failure occurred where the tube passed through the refractory hearth (floor) of the furnace. Although the furnace atmosphere was neutral with respect to the work, it had a carburizing potential relative to the radiant tubes. Analysis (visual inspection, 250x spectroscopic examination of specimens etched with mixed acids, metallographic examination, and chemical analysis) supported the conclusions that the premature failure of the tube by perforation at the hearth level resulted from (1) corrosion caused by sulfur contamination from the refractory cement in contact with the tube and (2) severe local overheating at the same location. Recommendations included replacing all tubes using a low sulfur refractory cement in installation and controlling burner positioning and regulation more closely to avoid excessive heat input at the hearth level.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001536
EISBN: 978-1-62708-229-7
... cracking (IGSCC) Nuclear power plants Nuclear reactor coolant piping Nuclear Pump seal wear rings Pump shaft cracking Stress corrosion cracking 304 UNS S30400 Cemented carbide Stress-corrosion cracking Dealloying/selective leaching 1. Introduction Approximately 113 nuclear electrical...
Abstract
Argonne National Laboratory has conducted analyses of failed components from nuclear power-generating stations since 1974. The considerations involved in working with and analyzing radioactive components are reviewed here, and the decontamination of these components is discussed. Analyses of four failed components from nuclear plants are then described to illustrate the kinds of failures seen in service. The failures discussed are (1) intergranular stress-corrosion cracking of core spray injection piping in a boiling water reactor, (2) failure of canopy seal welds in adapter tube assemblies in the control rod drive head of a pressurized water reactor, (3) thermal fatigue of a recirculation pump shaft in a boiling water reactor, and (4) failure of pump seal wear rings by nickel leaching in a boiling water reactor.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006795
EISBN: 978-1-62708-295-2
... of mixed behavior was created based on results (rounded silica sand of 0.1 to 0.3 mm, or 0.004 to 0.01 in., diameter; 61 m/s, or 200 ft/s, velocity) obtained for WC-15wt%Co cemented carbide consisting of brittle tungsten carbide grains and ductile cobalt matrix ( Ref 49 ). Erosion of a given material...
Abstract
Erosion is the progressive loss of original material from a solid surface due to mechanical interaction between that surface and a fluid, a multicomponent fluid, an impinging liquid, or impinging solid particles. The detrimental effects of erosion have caused problems in a number of industries. This article describes the processes involved in erosion of ductile materials, brittle materials, and elastomers. Some examples of erosive wear failures are given on abrasive erosion, liquid impingement erosion, cavitation, and erosion-corrosion. In addition, the article provides information on the selection of materials for applications in which erosive wear failures can occur.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001819
EISBN: 978-1-62708-180-1
... prostheses are anchored by using a bone cement in a bed that has been mechanically prepared in the remaining bone. Recently, various designs have been developed for the cementless anchoring of prostheses by a tight fit. Certain prosthesis systems have porous surface coatings on their shafts to increase...
Abstract
This article commences with a description of the prosthetic devices and implants used for internal fixation. It describes the complications related to implants and provides a list of major standards for orthopedic implant materials. The article illustrates the body environment and its interactions with implants. The considerations for designing internal fixation devices are also described. The article analyzes failed internal fixation devices by explaining the failures of implants and prosthetic devices due to implant deficiencies, mechanical or biomechanical conditions, and degradation. Finally, the article discusses the fatigue properties of implant materials and the fractures of total hip joint prostheses.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006765
EISBN: 978-1-62708-295-2
... cloths. For hard materials, such as through-hardened steels, ceramics, and cemented carbides, two rough-polishing steps may be sufficient. The initial rough-polishing step may be followed by polishing with 1 μm diamond on a napless, low-nap, or medium-nap cloth. A compatible lubricant should be used...
Abstract
Metallographic examination is one of the most important procedures used by metallurgists in failure analysis. Typically, the light microscope (LM) is used to assess the nature of the material microstructure and its influence on the failure mechanism. Microstructural examination can be performed with the scanning electron microscope (SEM) over the same magnification range as the LM, but examination with the latter is more efficient. This article describes the major operations in the preparation of metallographic specimens, namely sectioning, mounting, grinding, polishing, and etching. The influence of microstructures on the failure of a material is discussed and examples of such work are given to illustrate the value of light microscopy. In addition, information on heat-treatment-related failures, fabrication-/machining-related failures, and service failures is provided, with examples created using light microscopy.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003555
EISBN: 978-1-62708-180-1
..., ceria, zirconia, and/or niobia improve the scale adhesion and scale resilience to cyclic oxidation ( Ref 5 ). Carburization Carburization is the formation of carbide corrosion products on exposure to temperatures above approximately 760 °C (1400 °F) in gases containing methane, carbon monoxide...
Abstract
High temperature corrosion may occur in numerous environments and is affected by factors such as temperature, alloy or protective coating composition, time, and gas composition. This article explains a number of potential degradation processes, namely, oxidation, carburization and metal dusting, sulfidation, hot corrosion, chloridation, hydrogen interactions, molten metals, molten salts, and aging reactions including sensitization, stress-corrosion cracking, and corrosion fatigue. It concludes with a discussion on various protective coatings, such as aluminide coatings, overlay coatings, thermal barrier coatings, and ceramic coatings.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003551
EISBN: 978-1-62708-180-1
... those chemical and physical properties that make them applicable for structures, or as components of systems, that are exposed to environments above 538 °C (1000 °F).” Nowadays, refractories are made of not only oxides and nonoxide compounds (carbides, nitrides, and carbons), but also of metallic...
Abstract
This article provides a discussion on the structural ceramics used in gas turbine components, the automotive and aerospace industries, or as heat exchangers in various segments of the chemical and power generation industries. It covers the fundamental aspects of chemical corrosion and describes the corrosion resistance characteristics of specific classes of refractories and structural ceramics. The article also examines the prevention strategies that minimize corrosion failures of both classes of materials.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001516
EISBN: 978-1-62708-234-1
... of which are cemented to provide a gap for generating the recording field or collecting the media flux for writing and reading data, respectively. During the last decade the storage density of a magnetic disk-drive has doubled every 2.5 years on the average. Advances in materials, lubrication...
Abstract
This paper deals with disk drive failures that occur in the interface area between the head and disk. The failures often lead to the loss of stored data and are characterized by circumferential microscratches that are usually visible to the unaided eye. The recording media in disk drives consists of a metal, glass, ceramic, or plastic substrate coated with a magnetic material. Data errors are classified as ‘soft’ or ‘hard’ depending on their correctability. Examination has shown that hard errors are the result of an abrasive wear process that begins with contact between head and disk asperities. The contact generates debris that, as it accumulates, increases contact pressure between the read-write head and the surface of the disk. Under sufficient pressure, the magnetic coating material begins wearing away, resulting in data loss.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003532
EISBN: 978-1-62708-180-1
... polishing is conducted with 9, 6, or 3 μm diamond abrasives charged onto napless or low-nap cloths. For hard materials, such as through-hardened steels, ceramics, and cemented carbides, two rough-polishing steps may be required. The initial rough-polishing step may be followed by polishing with 1 μm diamond...
Abstract
This article provides a discussion on the metallographic techniques used for failure analysis, and on fracture examination in materials, with illustrations. It discusses various metallographic specimen preparation techniques, namely, sectioning, mounting, grinding, polishing, and electrolytic polishing. The article also describes the microstructure examination of various materials, with emphasis on failure analysis, and concludes with information on the examination of replicas with light microscopy.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001816
EISBN: 978-1-62708-180-1
...), the tube was renormalized. No chemical cleaning was performed, and the boiler operated for 16 years. After this service history, the microstructure was mildly spheroidized carbides, with pearlite colonies still well defined. Inside-diameter scale thickness indicated an average metal temperature of nearly...
Abstract
This article explains the main types and characteristic causes of failures in boilers and other equipment in stationary and marine power plants that use steam as the working fluid with examples. It focuses on the distinctive features of each type that enable the failure analyst to determine the cause and suggest corrective action. The causes of failures include tube rupture, corrosion or scaling, fatigue, erosion, and stress-corrosion cracking. The article also describes the procedures for conducting a failure analysis.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006825
EISBN: 978-1-62708-329-4
..., and outside-diameter and/or inside-diameter intergranular cracking or oxide penetration of the grain boundaries. The carbide phase of ferritic steels is fully spheroidized. Fig. 7 Microstructure showing (a) extensive transverse cracking adjacent to the main fracture (original magnification: ~4...
Abstract
Failures in boilers and other equipment taking place in power plants that use steam as the working fluid are discussed in this article. The discussion is mainly concerned with failures in Rankine cycle systems that use fossil fuels as the primary heat source. The general procedure and techniques followed in failure investigation of boilers and related equipment are discussed. The article is framed with an objective to provide systematic information on various damage mechanisms leading to the failure of boiler tubes, headers, and drums, supplemented by representative case studies for a greater understanding of the respective damage mechanism.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003569
EISBN: 978-1-62708-180-1
... Trans. , Vol 29 ( No. 4 ), 1985 , p 473 – 480 36. Okada T. and Hattori S. , Cavitation-Erosion of Aluminium Oxide and Silicon Carbide , JSME Int. J. , Vol 33 ( No. 3 ), 1990 , p 382 – 387 37. Okada T. , Cavitation Erosion of Ceramics , Jpn. J. Tribol. , Vol 41...
Abstract
This article considers two mechanisms of cavitation failure: those for ductile materials and those for brittle materials. It examines the different stages of cavitation erosion. The article explains various cavitation failures including cavitation in bearings, centrifugal pumps, and gearboxes. It provides information on the cavitation resistance of materials and other prevention parameters. The article describes two American Society for Testing and Materials (ASTM) standards for the evaluation of erosion and cavitation, namely, ASTM Standard G 32 and ASTM Standard G 73. It concludes with a discussion on correlations between laboratory results and service.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001617
EISBN: 978-1-62708-227-3
... cracking (SCC) ( Fig. 15 ), 10 or progression markings caused by variations in corrosion product due to changing environmental conditions during SCC. Fig. 13 TEM replica of a fracture surface of WC-3Co cemented carbide exhibiting Wallner lines (arrowed) 8 Fig. 14 TEM replica...
Abstract
Failures of various types of hydraulic couplings used to connect pipes in a naval vessel are described and used to illustrate some of the general procedures for failure analysis. Cracking of couplings, which were manufactured from nickel-aluminum- bronze extruded bar, occurred in both seawater and air environments. Cracks initiated at an unusually wide variety of sites and propagated in either longitudinal or circumferential directions with respect to the axis of the couplings. Fracture surfaces were intergranular and exhibited little or no sign of corrosion (for couplings cracked in air), and there was very limited plasticity. Macroscopic progression markings were observed on fracture surfaces of several couplings but were not generally evident. At very high magnifications, numerous slip lines, progression markings, and striations were observed. In a few cases, where complete separation had occurred in service, small areas of dimpled overload fracture were observed. It was concluded from these observations, and from comparisons of cracks produced in service with cracks produced by laboratory testing under various conditions, that cracking had occurred by fatigue. The primary cause of failure was probably the unanticipated presence of high-frequency stress cycles with very low amplitudes, possibly due to vibration, resonance, or acoustic waves transmitted through the hydraulic fluid. Secondary causes of failure included the presence of high tensile residual stresses in one type of coupling, undue stress concentrations at some of the crack-initiation sites, and overtorquing of some couplings during installation. Recommendations on ways to prevent further failures based on these causes are discussed.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006787
EISBN: 978-1-62708-295-2
... sulfur content to 1 ppm or less and small additions of lanthanum, yttrium, tantalum, cerium, zirconium, and/or niobium improve scale adhesion and scale resilience to cyclic oxidation ( Ref 8 ). Carburization Carburization is the formation of carbide corrosion products on exposure to temperatures...
Abstract
High-temperature corrosion can occur in numerous environments and is affected by various parameters such as temperature, alloy and protective coating compositions, stress, time, and gas composition. This article discusses the primary mechanisms of high-temperature corrosion, namely oxidation, carburization, metal dusting, nitridation, carbonitridation, sulfidation, and chloridation. Several other potential degradation processes, namely hot corrosion, hydrogen interactions, molten salts, aging, molten sand, erosion-corrosion, and environmental cracking, are discussed under boiler tube failures, molten salts for energy storage, and degradation and failures in gas turbines. The article describes the effects of environment on aero gas turbine engines and provides an overview of aging, diffusion, and interdiffusion phenomena. It also discusses the processes involved in high-temperature coatings that improve performance of superalloy.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003567
EISBN: 978-1-62708-180-1
... of energy consumed annually by U.S. industry for crushing and grinding purposes, whereas contributions from minerals account for 50%; cement, 25%; coal, 13%; and agricultural products, 12% ( Ref 5 ). The development of more efficient mining, transportation, and processing systems has allowed exploitation...
Abstract
This article focuses on the corrosion-wear synergism in aqueous slurry and grinding environments. It describes the effects of environmental factors on corrosive wear and provides information on the impact and three-body abrasive-corrosive wear. The article also discusses the various means for combating corrosive wear, namely, materials selection, surface treatments, and handling-environment modifications.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006785
EISBN: 978-1-62708-295-2
... and the morphology of cracks that develop, as illustrated by the intergranular SCC that occurs in sensitized austenitic stainless steel alloys and some higher-strength aluminum alloys. Sensitization occurs in some austenitic stainless steels when chromium carbides form at the austenite grain boundaries, which...
Abstract
Stress-corrosion cracking (SCC) is a form of corrosion and produces wastage in that the stress-corrosion cracks penetrate the cross-sectional thickness of a component over time and deteriorate its mechanical strength. Although there are factors common among the different forms of environmentally induced cracking, this article deals only with SCC of metallic components. It begins by presenting terminology and background of SCC. Then, the general characteristics of SCC and the development of conditions for SCC as well as the stages of SCC are covered. The article provides a brief overview of proposed SCC propagation mechanisms. It discusses the processes involved in diagnosing SCC and the prevention and mitigation of SCC. Several engineering alloys are discussed with respect to their susceptibility to SCC. This includes a description of some of the environmental and metallurgical conditions commonly associated with the development of SCC, although not all, and numerous case studies.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... be reduced on the surface of a more active metal—for example, copper on aluminum or steel, silver on copper. This process is also known as cementation, especially with regard to aluminum alloys. The resulting metallic deposit provides cathodic sites for further galvanic corrosion of the more active metal...
Abstract
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.
Book Chapter
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006939
EISBN: 978-1-62708-395-9
... for use. This results in a wide variety of surface-modifier applications across automotive, aerospace, electronics, engineering polymers, paint and coatings, cement and construction, biomedical, textile, and petrochemical industries ( Ref 45 ). Types of Surface Modifiers Surface modifiers can...
Abstract
Polymer materials are key building blocks of the modern world, commonly used in packaging, automobiles, building materials, electronics, telecommunications, and many other industries. These commercial applications of polymeric materials would not be possible without the use of additives. This article is divided into five sections: mechanical property modifiers, physical property modifiers, biological function modifiers, processing aids, and colorants. It describes three classes of additives that are used to inhibit biological activity, six classes of mechanical property modifiers, three classes of physical property modifiers, and two classes of both colorants and processing aids.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006782
EISBN: 978-1-62708-295-2
..., for example, carbides, sigma phase, untempered martensite, (etc.). Corrosion Debris Analysis After the overall examination, corrosion debris is collected from selected representative areas and analyzed. As mentioned previously, it is important that the corrosion debris is not contaminated during...
Abstract
Corrosion is the deterioration of a material by a reaction of that material with its environment. The realization that corrosion control can be profitable has been acknowledged repeatedly by industry, typically following costly business interruptions. This article describes the electrochemical nature of corrosion and provides the typical analysis of environmental- and corrosion-related failures. It presents common methods of testing of laboratory corrosion and discusses the processes involved in the prevention of environmental- and corrosion-related failures of metals and nonmetals.
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