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heat affected zone corrosion
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Image
Intergranular corrosion of the inside surface heat-affected zone of E-Brite...
Available to PurchasePublished: 01 January 2002
Fig. 36 Intergranular corrosion of the inside surface heat-affected zone of E-Brite stainless steel adjacent to the weld fusion line. Electrolytically etched with 10% oxalic acid. 100×
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Intergranular corrosion of the inside surface heat-affected zone of E-Brite...
Available to Purchase
in Leaking Welds in a Ferritic Stainless Steel Wastewater Vaporizer
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 3 Intergranular corrosion of the inside surface heat-affected zone of E-Brite stainless steel adjacent to the weld fusion line. Electrolytically etched with 10% oxalic acid. 100×
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Image
Intergranular corrosion of the inside surface heat-affected zone of E-Brite...
Available to PurchasePublished: 15 January 2021
Fig. 36 Intergranular corrosion of the inside surface heat-affected zone of E-Brite stainless steel adjacent to the weld fusion line. Electrolytically etched with 10% oxalic acid. Original magnification: 100×
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in Failure of Ship Hull Plate Attributed to Lamellar Tearing
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
Book Chapter
Grain Disintegration in a Welded Sheet Construction
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c9001223
EISBN: 978-1-62708-233-4
... prepared surface. It can be seen that in the lower sheet the steel in the limited region of the heat affected zone of the welded seam has been attacked from both sides. The sectional micrograph in Fig. 4 clearly shows the grain boundary break-up typical of grain disintegration. The intergranular cohesion...
Abstract
The corner of a welded sheet construction made from austenitic corrosion-resistant chromium-nickel steel showed corrosive attack of the outer sheet. This attack was most severe at the points subjected to the greatest heat during welding. Particularly large amounts of weld metal had been applied. Microscopic examination showed grain disintegration was promoted by the thickness of the weld bead and the amount of heat required to produce it. If nonstabilized austenitic sheet is to be used in the future, one of the particularly low-carbon steels, X2 CrNi 18 9 or X2 CrNiMo 18 10, is recommended.
Book Chapter
Biologically Influenced Corrosion of Stainless Steel Welds by Water
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001683
EISBN: 978-1-62708-234-1
... occurred at welds and consisted of large subsurface void formations with pinhole penetrations of the surfaces. Corrosive attack initiated in the heat affected zones of the welds, usually immediately adjacent to fusion lines. Stepwise grinding, polishing, and etching through the affected areas revealed...
Abstract
Corrosion in a closed-loop cooling water system constructed of austenitic stainless steel occurred during an extended lay up of the system with biologically contaminated water. The characteristics of the failure were those of microbiologically influenced corrosion (MIC). The corrosion occurred at welds and consisted of large subsurface void formations with pinhole penetrations of the surfaces. Corrosive attack initiated in the heat affected zones of the welds, usually immediately adjacent to fusion lines. Stepwise grinding, polishing, and etching through the affected areas revealed that voids generally grew in the wrought material by uniform general corrosion. Tunneling or worm-holing was also observed, whereby void extension occurred by initiating daughter voids probably at flaws or other inhomogeneities. Selective attack occurred within the fusion zone, i.e., within the cast two-phase structure of the weld filler itself. The result was a void wall which consisted of a rough and porous ferritic material, a consequence of preferential attack of the austenitic phase and slightly lower rate of corrosive attack of the ferrite phase. The three-dimensional spongy surface was studied optically and with the scanning electron microscope.
Book Chapter
“On-Load Corrosion” in Tubes of High Pressure Boilers
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001396
EISBN: 978-1-62708-229-7
...-side surface of tubes situated in zones exposed to radiant heat where high rates of heat transfer pertain. In most instances, a large number of adjacent tubes are found to have suffered, the affected zone frequently extending in a horizontal band across the boiler. In some instances, pronounced local...
Abstract
The phenomenon of on-load corrosion is directly associated with the production of magnetite on the water-side surface of boiler tubes. On-load corrosion may first be manifested by the sudden, violent rupture of a boiler tube, such failures being found to occur predominantly on the fire-side surface of tubes situated in zones exposed to radiant heat where high rates of heat transfer pertain. In most instances, a large number of adjacent tubes are found to have suffered, the affected zone frequently extending in a horizontal band across the boiler. In some instances, pronounced local attack has taken place at butt welds in water-wall tubes, particularly those situated in zones of high heat flux. To prevent on-load corrosion an adequate flow of water must occur within the tubes in the susceptible regions of a boiler. Corrosion products and suspended matter from the pre-boiler equipment should be prevented from entering the boiler itself. Also, it is good practice to reduce as far as possible the intrusion of weld flash and other impedances to smooth flow within the boiler tubes.
Book Chapter
Failure of Ship Hull Plate Attributed to Lamellar Tearing
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001141
EISBN: 978-1-62708-227-3
... of the weld considerable corrosion has taken place. Fig. 3 Double fillet weld between bulkhead and hull plate. Fig. 4 Weld between bulkhead and hull plate showing crack in heat-affected zone. A crack running in the heat-affected zone at a skewed T-butt partial penetration weld between...
Abstract
During a refit of a twenty-year-old Naval destroyer, two cracks were found on the inside of the killed carbon-manganese steel hull plate at the forward end of the boiler room. The cracks coincided with the location of the top and bottom plates of the bilge keel. Metallurgical examination of sections cut from the cracked area identified lamellar tearing as the principle cause of the cracking. This was surprising in 6 mm thick hull plates. Corrosion fatigue and general corrosion also contributed to hull plate perforation. Although it is probable that more lamellar tears exist near the bilge keel in other ships and may be a nuisance in the future, the hull integrity of the ships is not threatened and major repairs are not needed.
Book Chapter
Failure of a Flange from a High Pressure Feeder Plant
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001249
EISBN: 978-1-62708-236-5
... Individual pieces of the ruptured flange. Fig. 3 Inner side of a piece of broken flange. Bands of another smeared metal. Fig. 4 Cross section on the inner side of the flange. Cracks and broad heat affected zone. Etched (FeCl 3 + HCl + ethanol). 2.6 × Fig. 5 Cross section...
Abstract
The flanged bearing bush carrying the drive shaft of a feed pump suddenly fractured after about two years of service. The chemical composition was normal for high chromium ledeburitic cast steel, which was corrosion and wear resistant as well as refractory. For unknown reasons the rotating shaft came into direct contact with the flange. Mechanical friction caused a rise in temperature on both contact surfaces. This mutual contact lasted long enough for the temperature in the contact zone to exceed 1200 deg C, at which the flange material became softened or molten. As a result, considerable structural changes took place on the inner wall of the flange. Thermal stresses and excessive mechanical loads due to smearing of the flange material then led to fracture of the flange.
Book Chapter
Metallographic Examination of Microbiologically Influenced Corrosion in a Fire Truck Water Tank
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c9001704
EISBN: 978-1-62708-218-1
.... The examinations revealed a classic case of microbiologically influenced corrosion (MIC), which preferentially attacked the heat affected zones of the tank welds, resulting in the leaks. Heat affected zone Leakage Water tanks Welded joints 304 UNS S30400 Biological corrosion The experienced...
Abstract
Several type 304 stainless steel fire truck water tanks developed through-wall leaks after being in service for approximately two years. One representative tank underwent a comprehensive laboratory analysis, which included metallographic examinations and chemical analyses. The examinations revealed a classic case of microbiologically influenced corrosion (MIC), which preferentially attacked the heat affected zones of the tank welds, resulting in the leaks.
Book Chapter
Failure of a Stainless Steel Tank Used for Storage of Heavy Water/Helium
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001349
EISBN: 978-1-62708-215-0
... of factors resulted in failure by stress-corrosion cracking. Implementation of a new repair procedure was recommended. Repairs were successfully made using the new procedure, and all cracks in the weld repair zones were eliminated. Domes Heat-affected zone Nuclear reactor components Nuclear reactors...
Abstract
The dished ends of a heavy water/helium storage tank manufactured from 8 mm (0.3 in.) thick type 304 stainless plate leaked during hydrotesting. Repeated attempts at repair welding did not alleviate the problem. Examination of samples from one dished end revealed that the cracking was confined to the heat affected zone (HAZ) surrounding circumferential welds and, to a lesser extent, radial welds that were part of the original construction. Most of the cracks initiated and propagated from the inside surface of the dished ends. Microstructures of the base metal, HAZ, and weld metal indicated severe sensitization in the HAZ due to high heat input during welding. An intergranular corrosion test confirmed the observations. The severe sensitization was coupled with residual stresses and exposure of the assembly to a coastal atmosphere during storage prior to installation. This combination of factors resulted in failure by stress-corrosion cracking. Implementation of a new repair procedure was recommended. Repairs were successfully made using the new procedure, and all cracks in the weld repair zones were eliminated.
Book Chapter
Intergranular Corrosion in an E-Brite-Clad Ferralium Tube Sheet in Nitric Acid Service
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001047
EISBN: 978-1-62708-214-3
... Abstract An E-Brite /Ferralium explosively bonded tube sheet in a nitric acid condenser was removed from service because of corrosion. Visual and metallographic examination of tube sheet samples revealed severe cracking in the heat-affected zone between the outer tubes and the weld joining...
Abstract
An E-Brite /Ferralium explosively bonded tube sheet in a nitric acid condenser was removed from service because of corrosion. Visual and metallographic examination of tube sheet samples revealed severe cracking in the heat-affected zone between the outer tubes and the weld joining the tube sheet to the floating skirt. Cracks penetrated deep into the tube sheet, and occasionally into the tube walls. The microstructures of both alloys and of the weld appeared normal. Intergranular corrosion characteristic of end-grain attack was apparent. A low dead spot at the skirt / tube sheet joint allowed the Nox to condense and subsequently reboil. This, coupled with repeated repair welding in the area, reduced resistance to acid attack. Intergranular corrosion continued until failure. Recommendations included changing operating parameter inlet to prevent HNO3 condensation outside the inlet and replacement of the floating skirt with virgin material (i.e., material unaffected by weld repairs).
Image
Micrograph of intergranular stress-corrosion cracking in the head-to-shell ...
Available to PurchasePublished: 15 January 2021
Fig. 30 Micrograph of intergranular stress-corrosion cracking in the head-to-shell heat-affected zone of a secondary urea reactor. Oxide is present within the stress-corrosion crack (arrows). Original magnification: 50×
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Book Chapter
Intergranular Stress-Corrosion Cracking of Carbon Steel Pipe Welds in a Kamyr Continuous Digester Equalizer Line
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001061
EISBN: 978-1-62708-214-3
... and heat-affected zones (HAZs). Fracture/crack morphology was brittle and primarily intergranular and deposits at crack tips were primarily iron oxides with significant amounts of sodium compounds. On these bases, the cracking was characterized as intergranular stress-corrosion cracking (IGSCC). Corrosion...
Abstract
Schedule 80 low-carbon steel pipes used to transfer kraft liquor in a Kamyr continuous pulp digester failed within 18 months after installation. Visual and metallographic examinations established that the cracking initiated on the internal surfaces of the equalizer pipes in the welds and heat-affected zones (HAZs). Fracture/crack morphology was brittle and primarily intergranular and deposits at crack tips were primarily iron oxides with significant amounts of sodium compounds. On these bases, the cracking was characterized as intergranular stress-corrosion cracking (IGSCC). Corrosion-related deterioration was not found, indicating that the material was generally suitable for the intended service. High residual tensile stresses in the welds and HAZS, resulting from field welding under highly constrained conditions using inadequate weld procedures, were the most probable cause of the failures. Minimizing residual stresses through use of welding procedures that include appropriate preweld and interpass temperatures and postweld stress relief heat treatment at 650 deg C (1200 deg F) was recommended to prevent further failures.
Book Chapter
Impingement-Corrosion Failure of a Ferritic Malleable Iron Elbow
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0091402
EISBN: 978-1-62708-234-1
... for ferritizing malleable iron. This resulted in lower resistance to erosion and corrosion than pearlitic malleable iron. Recommendations included replacing the elbows with heat-treated fittings with a pearlitic malleable microstructure. Impingement erosion Pearlite Pipe bends ASTM A47 grade 35018 UNS...
Abstract
Leakage was detected in a malleable iron elbow (ASTM A 47, grade 35018) after only three months in service. Life expectancy for the elbow was 12 to 24 months. The piping alternately supplied steam and cooling water to a tire-curing press. The supply line and elbow were subjected to 14 heating and cooling cycles per hour for at least 16 h/day, or a minimum of 224 cycles/day. Steam and water pressure were 1035 kPa (150 psi) and 895 kPa (130 psi) respectively, and water-flow rate was estimated to be 1325 L/min (350 gal/min) based on pump capacity. Water-inlet temperature was 10 to 15 deg C (50 to 60 deg F) and outlet temperature was 50 to 60 deg C (120 to 140 deg F). The pH of the water was 6.9. Investigation (visual inspection, chemical analysis, and 67x nital etched micrographs) supported the conclusion that the elbows had been given the usual annealing and normalizing treatment for ferritizing malleable iron. This resulted in lower resistance to erosion and corrosion than pearlitic malleable iron. Recommendations included replacing the elbows with heat-treated fittings with a pearlitic malleable microstructure.
Book Chapter
Cracking of a Steam Pipe Flange
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001421
EISBN: 978-1-62708-235-8
... superimposing a fluctuating component on the residual stress; in addition, the condensate would wet the affected zone, so that the requisite conditions for the development of corrosion-fatigue failure would be present. It is significant that the flange of the attached valve, which would also be “drowned...
Abstract
The bottom flange of a vertical pipe coupled to an isolating valve in a steam supply line to a turbine failed. Steam pressure was 1,500 psi and the temperature 416 deg C (780 deg F). Multiple cracking occurred in the bore of the flange. A quarter-segment was cut out and examined. The cracks were located in the part of the flange that formed a continuation of the pipe bore. The majority of them originated at the end of the flange bore and extended axially along the pipe and radially across the flange face. Magnetic crack detection revealed a further number of cracks in the weld deposit. While the fracture in the weld metal was of the ductile type exhibiting a fine fibrous appearance, that in the flange material was of the cleavage type. Microscopic examination revealed that the cracks were blunt-ended fissures of the type characteristic of corrosion-fatigue. It was concluded that cracking was due to corrosion-fatigue, which arose from the combined effect of a fluctuating tensile stress in the presence of a mildly corrosive environment.
Book Chapter
Bacterial-Induced Corrosion of AISI Type 304 Stainless Steel Tanks
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001655
EISBN: 978-1-62708-220-4
... of the tank, mainly near weld toes. However, no general corrosion of the heat-affected zone was found. Metallographic sections were prepared through several of the pits and from noncorroded areas. The microstructure was found to be normal for 304L stainless steel, Figure 1 . In addition, no signs...
Abstract
This investigation involved two AISI 304L acid storage tanks and one AISI 304L spent solvent tank from a sewage treatment facility. After installation, these tanks were hydrostatically tested using sewage effluent. No leaks were found and after a year or two, the tanks were drained and filled with nitric acid in preparation for service. Three weeks later the two acid tanks were found to be leaking from the bottom. Samples from the spent solvent tank revealed that pitting was located in a depressed area near a suction hole, beneath a black residue. It was concluded that the acid tanks failed by chloride-induced pitting initiated by microbial activity. Further, the spent solvent tank failed by a similar, but anaerobic mechanism. The use of the effluent for the hydrostatic test and the failure to remove it and clean and dry the tanks was the primary cause of failure. Localized carbide segregation in the original plate served as preferential corrosion sites. Had the tanks been hydrostatically tested in a proper manner, the pitting may not have occurred.
Image
Duplex stainless steel 2205 stress-corrosion cracks in the heat-affected zo...
Available to PurchasePublished: 30 August 2021
Fig. 50 Duplex stainless steel 2205 stress-corrosion cracks in the heat-affected zone of the vessel
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Book Chapter
Failure of a Tank Coupling
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0089339
EISBN: 978-1-62708-233-4
..., heat-affected zone, and base metal. The branching and transgranular cracking was found to emanate primarily from the exterior of the tank. It was concluded that the tank failed as a result of stress-corrosion cracking that initiated at the exterior surface as aqueous chlorides, especially within...
Abstract
Leakage was identified around a coupling welded into a stainless steel holding tank that stored condensate water with low impurity content. The tank and fitting were manufactured from type 304 stainless steel. The coupling joint consisted of an internal groove weld and an external fillet weld. Cracking was found to be apparent on the tank surface, adjacent to the coupling weld. Chlorine, carbon, and oxygen in addition to the base metal elements were revealed by energy-dispersive x-ray spectrometric analysis. A great number of secondary, branching cracks were evident in the weld, heat-affected zone, and base metal. The branching and transgranular cracking was found to emanate primarily from the exterior of the tank. It was concluded that the tank failed as a result of stress-corrosion cracking that initiated at the exterior surface as aqueous chlorides, especially within an acidic environment, have been shown to cause SCC in austenitic stainless steels under tensile stress.
Book Chapter
Alloy 430 Ferritic Stainless Steel Welds Fail due to Stress-Corrosion Cracking in Heat-Recovery Steam Generator
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001609
EISBN: 978-1-62708-229-7
... of its resistance to chloride and sulfuric acid dewpoint corrosion under conditions potentially present in the HRSG low-pressure feedwater economizer. Intergranular corrosion and cracking were found in the weld metal and heat-affected zones. The hardness in these regions was up to 35 HRC, and the weld...
Abstract
Alloy 430 stainless steel tube-to-header welds failed in a heat recovery steam generator (HRSG) within one year of commissioning. The HRSG was in a combined cycle, gas-fired, combustion turbine electric power plant. Alloy 430, a 17% Cr ferritic stainless steel, was selected because of its resistance to chloride and sulfuric acid dewpoint corrosion under conditions potentially present in the HRSG low-pressure feedwater economizer. Intergranular corrosion and cracking were found in the weld metal and heat-affected zones. The hardness in these regions was up to 35 HRC, and the weld had received a postweld heat treatment (PWHT). Metallographic examination revealed that the corroded areas contained undertempered martensite. Fully tempered weld areas with a hardness of 93 HRB were not attacked. No evidence of corrosion fatigue was found. Uneven temperature control during PWHT was the most likely cause of failure.
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