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corrosion cavities
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in Failure of an Inconel Clad Carbon Steel Inlet Cone of the Pandia Digester
> ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment
Published: 01 June 2019
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in Corrosion Failures in Gas Turbine Hot Components
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
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in Corrosion Failures in Gas Turbine Hot Components
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 5 ( a ) Macrograph showing the appearance of corrosion cavities, ( b ) macrograph showing the appearance and EDS analysis of local corrosion cavities in different locations: 1—oxide scale, 2—subscale sulfide particles, 3—remaining coating, not affected by corrosion
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in Failure of an Inconel Clad Carbon Steel Inlet Cone of the Pandia Digester
> ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment
Published: 01 June 2019
Fig. 3 Metallographic cross section of erosion/corrosion cavity in the Inconel cladding. Magnification 4×
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in Failure of an Inconel Clad Carbon Steel Inlet Cone of the Pandia Digester
> ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment
Published: 01 June 2019
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c9001563
EISBN: 978-1-62708-230-3
... steel with 0.075-inch thick Inconel cladding alloy 600. The failure was caused by an erosion/corrosion leak at the midsection ( Fig. 1 ). Erosion/corrosion was confined to a localized area directly facing the steam inlet nozzle. The erosion/corrosion cavities were smooth-bottomed pits ( Figs. 2 and 3...
Abstract
An Inconel-clad SA-212 Grade B carbon steel inlet cone with an anticipated 25-year service life failed in a localized area after only seven years of service. The failure was caused by an erosion/corrosion leak at the midsection. Erosion/corrosion was confined to a localized area directly facing the steam inlet nozzle. The Inconel cladding was intact elsewhere in the inlet cone with insignificant corrosion-related degradation. In the absence of the conditions that led to erosion/corrosion, the Inconel clad carbon steel was considered adequate for the intended service. As a corrective measure, a solid Inconel liner was recommended in the areas of direct steam impingement.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001827
EISBN: 978-1-62708-241-9
... of high-temperature oxidation on the hot corrosion process. Preventative measures are also discussed. gas turbine thermal fatigue cracking hot corrosion superalloys corrosion cavities spark optical emission spectrometry operating temperature GTD 111 (cast nickel-base superalloy) FSX 414...
Abstract
Gas turbines and other types of combustion turbomachinery are susceptible to hot corrosion at elevated temperatures. Two such cases resulting in the failure of a gas turbine component were investigated to learn more about the hot corrosion process and the underlying failure mechanisms. Each component was analyzed using optical and scanning electron microscopy, energy dispersive spectroscopy, mechanical testing, and nondestructive techniques. The results of the investigation provide insights on the influence of temperature, composition, and microstructure and the contributing effects of high-temperature oxidation on the hot corrosion process. Preventative measures are also discussed.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001297
EISBN: 978-1-62708-215-0
... and numerous trails of corrosion pits were located on the spar cavity's inner surfaces. The corrosion pitting resulted from the failure of the thermoset seal in the spar shank cavity. The seal failure allowed moisture to enter into the cavity. The moisture then served as an electrolyte for galvanic corrosion...
Abstract
A helicopter tail rotor blade spar failed in fatigue, allowing the blade to separate during flight. The 2014-T652 aluminum alloy blade had a hollow spar shank filled with lead wool ballast and a thermoset polymeric seal. A corrosion pit was present at the origin of the fatigue zone and numerous trails of corrosion pits were located on the spar cavity's inner surfaces. The corrosion pitting resulted from the failure of the thermoset seal in the spar shank cavity. The seal failure allowed moisture to enter into the cavity. The moisture then served as an electrolyte for galvanic corrosion between the lead wool ballast and the aluminum spar inner surface. The pitting initiated fatigue cracking which led to the spar failure.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001454
EISBN: 978-1-62708-220-4
... condition. There was no evidence of cracking of the material in the region of the blisters and bend tests demonstrated it possessed satisfactory ductility. The primary cause of the blistering was ascribed to the presence of discontinuities within the plate. This provided cavities in which the hydrogen...
Abstract
The interior of a cylindrical tank used for the road transport of concentrated sulfuric acid revealed severe blistering of the plates, mainly over the crown and more particularly on the first ring. The tank, made in 1958, was of welded construction, the material being mild steel plate. Some of the blisters were pierced by drilling a hole in the center and at the same time applying a small flame. In several cases combustion of the escaping gas caused minor explosions, a result characteristic of hydrogen. Etching showed the material to be a low-carbon steel in the partly spheroidized condition. There was no evidence of cracking of the material in the region of the blisters and bend tests demonstrated it possessed satisfactory ductility. The primary cause of the blistering was ascribed to the presence of discontinuities within the plate. This provided cavities in which the hydrogen was able to accumulate and build up pressure. Had the material been free from discontinuities of appreciable size, the blistering would not have occurred.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001234
EISBN: 978-1-62708-232-7
... Abstract In a copper hot water system, a bent pipe was soldered into a straight pipe with twice the diameter. The neighborhood of the soldered joint was covered with corrosion product predominantly blue-green in color, presumably carbonates. When these corrosion products were scratched off...
Abstract
In a copper hot water system, a bent pipe was soldered into a straight pipe with twice the diameter. The neighborhood of the soldered joint was covered with corrosion product predominantly blue-green in color, presumably carbonates. When these corrosion products were scratched off it was seen that the copper beneath this layer had not suffered noticeable attack. The object of the examination was the localized deep cavities located almost symmetrically to both sides of the inserted end of the narrower tube on the internal wall of the wider tube which had in one place been eaten right through. The symmetrical location on each side of the point of insertion of the narrower pipe and the localized sharp delineation of the attack indicated erosion due to the formation of turbulence. By avoiding sharp transitions and abrupt changes in cross section it is possible to design the pipe work so that localized turbulence is obviated. Degassing and cleansing of the water also would reduce the danger of erosion particularly in the case of softened water, which takes up oxygen and carbon dioxide very readily thus becoming particularly aggressive.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001808
EISBN: 978-1-62708-241-9
... organisms [ 3 ]. However, if sulfur or manganese is naturally present in the environment or as a constituent of the metal, these elements cannot be used as a sure sign of MIC. Morphology of the corrosion can be another sign of bacterial growth. Subsurface pitting or cavities can be found in MIC-attributed...
Abstract
Six cases of failure attributed to microbiologically influenced corrosion (MIC) were analyzed to determine if any of the failures could have been avoided or at least predicted. The failures represent a diversity of applications involving typical materials, primarily stainless steel and copper alloys, in contact with a variety of liquids, chemistries, and substances. Analytical techniques employed include stereoscopic examination, energy dispersive x-ray spectroscopy (EDS), temperature and pH testing, and metallographic analysis. The findings indicate that MIC is frequently the result of poor operations or improper materials selection, and thus often preventable.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001298
EISBN: 978-1-62708-215-0
... in.) deep and 0.254 mm (0.010 in.) across at the surface of the spar cavity. No significant amounts of corrosion product were found in the pit. Examination of other spar cavity surfaces revealed numerous smaller corrosion pits. All of the pits were filled with corrosion-preventative primer. Figure 4...
Abstract
A helicopter tail rotor blade spar failed in fatigue, allowing the outer section of the blade to separate in flight. The 7075-T7351 aluminum alloy blade had fiberglass pockets. The blade spar was a hollow “D” shape, and corrosion pits were present on the inner surface of the hollow spar A single corrosion pit, 0.38 mm (0.015 in.) deep, led to a fatigue failure of the spar The failure initiated on the pylon side of the blade. Dimensional analysis of the spar near the failure revealed measurements within engineering drawing tolerances. Though corrosion pitting was present, there was an absence of significant amounts of corrosion product and all of the pits were filled with corrosion-preventative primer. This indicated that the pitting occurred during spar manufacture, prior to the application of the primer The pitting resulted from multiple nickel plating and defective plating removal by acid etching. Post-plating baking operations subsequently reduced the fatigue strength of the spar.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0047611
EISBN: 978-1-62708-220-4
... seam weld. The cavity shown resulted from crevice corrosion and extended longitudinally below the inner surface of the weld. 60× Conclusions The tubes failed by crevice corrosion. The failed tubes were defective as-received, and the establishment of concentration cells within the longitudinal...
Abstract
Several tubes in a tube bundle in an evaporator used to concentrate an acid nitrate solution failed by leakage. The feed to the evaporator contained about 6% nitrate, and the discharge about 60% nitrate. The tube bundle was comprised of type 309S (Nb) stainless steel drawn-and-welded tubes expanded and welded into two type 304L stainless steel tube sheets. The tubes failed by crevice corrosion. The failed tubes were defective as-received, and the establishment of concentration cells within the longitudinal cracks in the seam welds led to ultimate corrosive penetration of the wall. There was no evidence of crevice corrosion or any localized penetration of tubes that had sound welds. The leaking type 309S (Nb) welded tubes should be replaced with seamless tubes of type 304L stainless steel to minimize the areas requiring welding and to provide maximum weldability for the tube-sheet joints.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001402
EISBN: 978-1-62708-220-4
... Abstract Weld-decay and stress-corrosion cracking developed in several similar all-welded vessels fabricated from austenitic stainless steel. During a periodic examination cracks were revealed at the external surface of one of the vessels. External patch welds had been applied...
Abstract
Weld-decay and stress-corrosion cracking developed in several similar all-welded vessels fabricated from austenitic stainless steel. During a periodic examination cracks were revealed at the external surface of one of the vessels. External patch welds had been applied at these and several other corresponding locations. Cracks visible on the external surface developed from the inside in a region close to the toe of the internal fillet weld to the deflector plate, and another deep crack associated with a weld cavity is visible slightly to the right of the main fissure. Microscopic examination revealed that precipitation of carbides at the grain boundaries had taken place in the vicinity of the cracks, but that the paths of the cracks were not wholly intergranular. Conditions present in the vicinity of the internal fillet weld must have been such as to favor both inter- and transgranular cracking. It is probable that the heating associated with the repair welds made from time to time also contributed to the trouble. The transgranular cracks, however, were indicative of stress-corrosion cracking.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001169
EISBN: 978-1-62708-220-4
... was approximately 175 deg C and it was cooled by water at 3 atm. Examination of two sections of the coil showed pinhead size pitting cavities at the exterior surface and partially parallel and partially angled array of fine cracks on external as well as the internal surfaces of the bend. Metallographic examination...
Abstract
Austenitic stainless steel (X 10 Cr-Ni-Mo-Ti 18 10, Material No. 1.4571) cooling coils were found leaking in 15 spots after eight weeks of service in an apparatus in which ammonium sulfide solution was converted into ammonium sulfate. The external temperature of the coil was approximately 175 deg C and it was cooled by water at 3 atm. Examination of two sections of the coil showed pinhead size pitting cavities at the exterior surface and partially parallel and partially angled array of fine cracks on external as well as the internal surfaces of the bend. Metallographic examination conducted on longitudinal and transverse sections showed predominantly transcrystalline cracks, originated from the pits at the external surfaces of the pipe. Their appearance suggested they were stress corrosion cracks that occur in austenitic steels under the combined effect of stresses and certain corrosion agents, especially chlorides. If chlorides were absent, hydrogen sulfide which causes similar pitting and is capable of causing cracks could be suspected. Favorable state of stresses, which could be residual or due to heat treating, bending or straightening operations, would be recommended for better behavior of the container.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001365
EISBN: 978-1-62708-215-0
.... The chlorine (chloride) increases the pitting potential within the pre-existing shrinkage cavities. The copper and nickel are possible indicators of corrosion in water circuit heat exchangers. Fig. 10 Typical results of in situ EDS analyses at the base of shrinkage voids in the impeller Mechanical...
Abstract
An investigation was conducted to determine the cause of numerous cracks and other defects on the surface of a cast ASTM A743 grade CA-15 stainless steel main boiler feed pump impeller. The surface was examined using a stereomicroscope, and macrofractography was conducted on several cross sections removed from the impeller body. Areas that appeared to have the most severe surface damage were sectioned, fractured open, and examined using SEM. The chemistry of the impeller and an apparent repair weld were also analyzed. The examination indicated that the cracks were shrinkage voids from the original casting process. Surface repair welds had been used to fill in or cover over larger shrinkage cavities. It was recommended that more stringent visual and nondestructive examination criteria be established for the castings.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0089663
EISBN: 978-1-62708-229-7
... defect was observed adjoining a tapped hole. A second, much larger cavity was also detected. Investigation (visual inspection and 7500x SEM fractographs) supported the conclusions that failure occurred through a zone of structural weakness that was caused by internal casting defects and a tapped hole...
Abstract
A crack was discovered in a cast steel (ASTM A 356, grade 6) steam turbine casing during normal overhaul of the turbine. The mechanical properties of the casting all exceeded the requirements of the specification. When the fracture surface was examined visually, an internal-porosity defect was observed adjoining a tapped hole. A second, much larger cavity was also detected. Investigation (visual inspection and 7500x SEM fractographs) supported the conclusions that failure occurred through a zone of structural weakness that was caused by internal casting defects and a tapped hole. The combination of cyclic loading (thermal fatigue), an aggressive service environment (steam), and internal defects resulted in gradual crack propagation, which was, at times, intergranular-with or without corrosive attack-and, at other times, was transgranular.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001370
EISBN: 978-1-62708-215-0
... on the fracture surface. The fracture surface was helical in shape, smooth, and flat. Some portion of the fracture surface was found to have been rubbed. A cavity near the center was observed ( Fig. 3 ). The presence of corrosion deposits masked the macroscopic fracture details. After cleaning with 50...
Abstract
A service water pump in a nuclear reactor failed when its shaft gave way. The fracture originated in the threaded portion of the sleeve nut on the drive-end side of the shaft. Results of the failure analysis showed that the cracking initiated at the thread root as a result of corrosion fatigue. Crack propagation occurred either by corrosion or mechanical fatigue. Evidence was found indicating high rotary bending stresses on the shaft during operation. The nonstandard composition of the En 8 steel used in the shaft and irregular maintenance reduced the life of the shaft. Recommendations included use of a case-hardened En 8 steel with the correct composition and regular maintenance of the pump.
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in Crevice-Corrosion Failure of Evaporator Tubes Because of Defective Seam Welds
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 1 Section through a type 309S (Nb) stainless steel evaporator tube containing a defective seam weld. The cavity shown resulted from crevice corrosion and extended longitudinally below the inner surface of the weld. 60×
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Published: 01 January 2002
Fig. 8 Elongated surface cavities on the inside surface of a 70-30 cupronickel tube produced by erosion-corrosion. The tube surface is clean, the attack having occurred due to brine flowing through it at 70 °C (158 °F) with turbulent flow and an excessive level of dissolved oxygen.
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