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coefficient of thermal expansion
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Published: 15 May 2022
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Published: 15 May 2022
Fig. 21 Effect of glass addition on coefficient of thermal expansion. PBT, polybutylene terephthalate; PC, polycarbonate
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Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006932
EISBN: 978-1-62708-395-9
... a consequence of high coefficients of thermal expansion and low thermal diffusivities. Although time-consuming techniques can be used to analyze thermal stresses, several useful qualitative tests are described in this article. The classification of internal stresses in plastic parts is covered. The article...
Abstract
Engineering plastics, as a general class of materials, are prone to the development of internal stresses which arise during processing or during servicing when parts are exposed to environments that impose deformation and/or temperature extremes. Thermal stresses are largely a consequence of high coefficients of thermal expansion and low thermal diffusivities. Although time-consuming techniques can be used to analyze thermal stresses, several useful qualitative tests are described in this article. The classification of internal stresses in plastic parts is covered. The article describes the effects of low thermal diffusivity and high thermal expansion properties, and the variation of mechanical properties with temperature. It discusses the combined effects of thermal stresses and orientation that result from processing conditions. The article also describes the effect of aging on properties of plastics. It explains the use of high-modulus graphite fibers in amorphous polymers.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001593
EISBN: 978-1-62708-234-1
... in coefficients of thermal expansion between the polysulfone and the mating steel insert. Coefficient of thermal expansion Insert molding Plastic Polysulfone Brittle fracture Introduction A flow sensor was submitted for analysis because the plastic body section had failed while in service...
Abstract
A failure analysis was conducted on a flow-sensing device that had cracked while in service. The polysulfone sensor body cracked radially, adjacent to a molded-in steel insert. This article describes the investigative methods used to conduct the failure analysis. The techniques utilized included scanning electron microscopy, Fourier transform infrared spectroscopy, differential scanning calorimetry, thermomechanical analysis, and melt flow rate determination. It was the conclusion of the investigation that the part failed via brittle fracture, with evidence also indicating low cycle fatigue associated with cyclic temperature changes from normal service. The design of the part and the material selection were significant contributing factors because of stresses induced during molding, physical aging of the amorphous polysulfone resin, and the substantial differential in coefficients of thermal expansion between the polysulfone and the mating steel insert.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0048772
EISBN: 978-1-62708-220-4
... through the fireside edge of the fracture surface. Scale was observed over most of the crack path which acted as a stress raiser. The effect of the oxide was magnified during thermal cycles because of differential thermal expansion, with the steel having a greater expansion coefficient than the scale...
Abstract
A return bend (made from ASTM A213, grade T11, ferritic steel) from a triolefin-unit heater ruptured after two years in service. The unit operated at 2410 kPa, with a hydrocarbon feed stream (85% propylene) entering at 260 to 290 deg C and leaving at 425 to 480 deg C. The fracture was found to terminate at the welds that joined the bend to the pipeline. A high concentration of both small and large inclusions was exhibited by the metallographic examination of the steel near the fracture. Branched cracks similar to those produced by stress corrosion of steel were observed in a section through the fireside edge of the fracture surface. Scale was observed over most of the crack path which acted as a stress raiser. The effect of the oxide was magnified during thermal cycles because of differential thermal expansion, with the steel having a greater expansion coefficient than the scale. It was recommended that material that is intended for critical applications where failure cannot be tolerated should be non-destructively examined.
Image
in Characterization of Thermosetting Resins and Polymers
> Characterization and Failure Analysis of Plastics
Published: 15 May 2022
Fig. 19 Idealized thermomechanical analysis curve in the expansion mode. α, coefficient of thermal expansion; T g , glass transition temperature. Source: Ref 7
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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.c9001811
EISBN: 978-1-62708-241-9
... coefficient of thermal expansion 28Cr3SiNiWMoV (chromium hot-worked steel) Introduction The increase in temperature increases the thermal vibration pushing the atoms apart, increasing their mean spacing, and causing thermal expansion ( α ). Perhaps the most important physical property of steel...
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.
Image
in Failure Analysis of a Polysulfone Flow Sensor Body — A Case Study
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 5 TMA plot overlay showing the differential in the coefficients of thermal expansion between the plastic collar material and the steel insert
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001570
EISBN: 978-1-62708-220-4
... be aggravated due to the lack of isotropy of titanium, which has a hexagonal crystal structure 3 . The difference in the thermal expansion coefficient of carbon steel and titanium might have played an important part in the loosening of the joint. The thermal expansion coefficient of carbon steel is over 30...
Abstract
Corrosion failure occurred in a titanium clad tubesheet because of a corrosive tube-side gas-liquid mixture leaking through fatigue cracks in the seal welds at tube-to-tubesheet joints. The tubesheet was a carbon steel plate clad with titanium on the tube side face. The seal weld cracks were initiated by cyclic stress imposed by exchanger tubes. The gas-liquid mixture passed through cracks under tube-side pressure, resulting in severe corrosion of the steel backing plate. The failure started with the loosening of the expanded tube-to-tubesheet joints. Loose joints allowed the exchanger tubes to impose load on seal welds and the shell side cooling water entered the crevice between the tubesheet and the tubes. The cooling water in the crevice caused galvanic reaction and embrittlement of seal welds. Brittle crack opening and crack propagation in seal welds occurred due to the cyclic stress imposed by the tubes. The cyclic stress arised from the thermal cycling of the heat exchanger. The possible effects of material properties on the failure of the tubesheet are discussed.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006923
EISBN: 978-1-62708-395-9
... Coefficient of thermal expansion, 10 −6 /°C °C °F °C °F W/m · K Btu/ft · h · °F Acrylonitrile-butadiene-styrene (ABS) 99 210 60 140 0.27 0.16 53 ABS-polycarbonate alloy (ABS-PC) 115 240 60 140 0.25 0.14 35 Diallyl phthalate (DAP) 285 545 130 265 0.36 0.21 27...
Abstract
This article discusses the thermal properties of engineering plastics and elastomers with respect to chemical composition, chain configuration, and base polymer conformation as determined by thermal analysis. It describes the processing of base polymers with or without additives and their response to chemical, physical, and mechanical stresses whether as an unfilled, shaped article or as a component of a composite structure. It summarizes the basic thermal properties of thermoplastics and thermosets, including thermal conductivity, temperature resistance, thermal expansion, specific heat, and glass transition temperature. It also provides information on polyimide and bismaleimide resin systems. Representative examples of different types of engineering thermoplastics are discussed primarily in terms of structure and thermal properties.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001852
EISBN: 978-1-62708-241-9
... 3 Module of elasticity 170 GPa Poisson’s ratio 0.31 Thermal expansion 14 E-6/°C Thermal conductivity 90.7 J/m °C Thermal capacity 444 J/kg °C The displacement boundary conditions were two types. First, the common practice of bolting the mould to a steel frame carrier...
Abstract
A 2–3 mm thick electroformed nickel mold showed early cracking under thermal load cycles. To determine the root cause, investigators obtained monotonic and cyclic properties of electroformed nickel at various temperatures and identified possible fatigue mechanisms. With the help of finite element modeling, they analyzed the material as well as the design and in-service application of the mold. They discovered that overconstraining the mold, while it was in service, caused excessive thermal stresses which accelerated crack initiation and propagation. Investigators also proposed remedies to prevent additional failures.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.9781627081801
EISBN: 978-1-62708-180-1
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0006548
EISBN: 978-1-62708-180-1
... opening displacements COV coefficient of variation CPSC Consumer Product Safety Commission CTE coefficient of thermal expansion CTOD crack-tip opening displacement CVD chemical vapor deposition CVN Charpy V-notch (impact test or speci- men) d depth; diameter da/dN fatigue crack growth rate da/dt crack...
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
... of the steam-air mixture. Conclusion and Recommendations Most Probable Cause Both fractographic and metallographic features revealed that failure was by thermal fatigue caused by the presence of biaxial thermal stresses on the inner surface of the tube. Because of their higher coefficient of thermal...
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 Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001816
EISBN: 978-1-62708-180-1
...-corrosion cracking (SCC) and hydrogen damage; fracture, including fatigue fracture, thermal fatigue fracture, and stress rupture; and distortion, especially distortion involving thermal-expansion effects or creep. The causes of failure can generally be classified as design defects; fabrication defects...
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.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0090451
EISBN: 978-1-62708-218-1
... in excess of the stated drying temperature. Further analysis of the assembly materials using thermomechanical analysis (TMA) produced significantly different results for the PET jacket and the steel housing material. Determination of the coefficients of thermal expansion (CTEs) showed approximately...
Abstract
Cracking occurred within the plastic jacket (injection molded from an impact-modified, 15% glass-fiber-reinforced PET resin.) of several assemblies used in a transportation application during an engineering testing regimen which involved cyclic thermal shock (exposing the parts to alternating temperatures of -40 and 180 deg C (-40 and 360 deg F)). Prior to molding, the resin had reportedly been dried at 135 deg C (275 deg F). The drying process usually lasted 6 h, but occasionally, the material was dried overnight. Comparison investigation (visual inspection, 20x SEM views, micro-FTIR, and analysis using DSC and TGA) with non-failed parts supported the conclusion that that the failure was via brittle fracture associated with the exertion of stresses that exceeded the strength of the resin as-molded caused by the disparity in the CTEs of the PET jacket and the mating steel sleeve. The drying process had exposed the resin to relatively high temperatures, which caused substantial molecular degradation, thus limiting the part's ability to withstand the stresses. The drying temperature was found to be significantly higher than the recommendation for the PET resin, and the testing itself exposed the parts to temperatures above the recognized limits for PET.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006869
EISBN: 978-1-62708-395-9
.... In addition to poor thermal conductivity, the higher thermal expansion coefficients of polymers (10 times greater than those of metals) and strong creeping tendency create problems related to dimensional clearances and stiffness. Polymers show poor compressive strengths (approximately 30 times less) compared...
Abstract
Reinforced polymers (RPs) are widely used in structural, industrial, automotive, and engineering applications due to their ecofriendly nature and the potential to manipulate their properties. This article addresses the technical synthesis of RPs, referring to their tribological behavior, to provide insights into the contribution and interaction of influential parameters on the wear behavior of polymers. It provides a brief discussion on the effects of significant parameters on RP tribology. The article describes abrasive and adhesive wear and provides a theoretical synthesis of the literature regarding the wear mechanisms of RPs. It also describes the synthesis of abrasive wear failure of different types of RPs and highlights the contribution of these influential parameters. The article addresses the synthesis of adhesive wear failure of different types of RPs.
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
...), increases in inside-diameter scale thickness, or decreases in steam-side heat-transfer coefficient caused by reduced flow will lead to tube metal temperature increases. Table 4 lists the range of values for heat-transfer coefficients and thermal-conductivity values for internal deposits. Heat...
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 Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001358
EISBN: 978-1-62708-215-0
... defects, caused by either no filler metal or lack of penetration, also led to fatigue cracking. The weld HAZs contained high residual stresses because of: Difference in coefficients of thermal expansion between the base metal (martensitic) and the weld metal (austenitic) Improper postweld heat...
Abstract
Several compressor diaphragms from five gas turbines cracked after a short time in service. The vanes were constructed of type 403 stainless steel, and welding was performed using type 309L austenitic stainless steel filler metal. The fractures originated in the weld heat-affected zones of inner and outer shrouds. A complete metallurgical analysis was conducted to determine the cause of failure. It was concluded that the diaphragms had failed by fatigue. Analysis suggests that the welds contained high residual stresses and had not been properly stress relieved. Improper welding techniques may have also contributed to the failures. Use of proper welding techniques, including appropriate prewelding and postwelding heat treatments, was recommended.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001668
EISBN: 978-1-62708-232-7
... checked after the accident and found to be fully operational. If a runaway temperature condition occurred, both vessels should have responded similarly. This did not occur. A check was made on the differences in the thermal coefficients of expansion between the autoclave and bolt material...
Abstract
A detailed investigative failure analysis was conducted on an autoclave which blew apart in a furnace for no apparent reason. Bolt failure resulted in separation of the autoclave lid and subsequent destruction of the furnace. Analysis using metallography, fractography, mechanical testing and exemplar tests were performed on the bolt material. Mechanical engineering analysis and leak-before-break criteria were extensively analyzed. Results led to only one possible conclusion: that an explosion occurred within the autoclave. Suggestions for autoclave design are presented as a result of the analysis.
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