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Book Chapter
A Microstructural Examination of Hot Corrosion of a Co-Cr-Fe Alloy Cast Burner Nozzle from a Coal Gasification Plant
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001681
EISBN: 978-1-62708-234-1
... Abstract A microstructural analysis has been made of a burner nozzle removed from service in a coal gasification plant. The nozzle was a casting of a Co-29wt%Cr-19wt%Fe alloy. Extensive hot corrosion had occurred on the surface. There was penetration along grain boundaries, and corrosion...
Abstract
A microstructural analysis has been made of a burner nozzle removed from service in a coal gasification plant. The nozzle was a casting of a Co-29wt%Cr-19wt%Fe alloy. Extensive hot corrosion had occurred on the surface. There was penetration along grain boundaries, and corrosion products in these regions were particularly rich in S, and also contained Al, Si, O, and Cl. The grain boundaries contained Cr-rich particles which were probably Cr23-C6 type carbides. In the matrix, corrosion occurred between the Widmanstatten plates. Particles were found between these plates, most of which were rich in Cr and O, and probably were Cr2-O3 oxides. Other matrix particles were found which were rich in Al, O, and S. The corrosion was related to these grain boundary and matrix particles, which either produced a Cr-depleted zone around them or were themselves attacked.
Book Chapter
Hot Corrosion of Stage 1 Nozzles in an Industrial Gas Turbine
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001281
EISBN: 978-1-62708-215-0
... of hot corrosion caused by a combination of contaminants, cooling-hole blockage, and coating loss. Hot gas corrosion X-40 UNS R30031 High-temperature corrosion and oxidation Background The first-stage nozzles of a high-pressure turbine (HPT) section of an industrial gas turbine exhibited...
Abstract
The first-stage nozzles of a high-pressure turbine section of an industrial gas turbine exhibited leading and trailing-edge deterioration. The nozzles were made of X-40, a cobalt-base alloy, and were aluminide coated. Failure analysis determined that the deterioration was the result of hot corrosion caused by a combination of contaminants, cooling-hole blockage, and coating loss.
Book Chapter
Hot Corrosion of Stainless Steel Grate Bars in Taconite Indurators
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001109
EISBN: 978-1-62708-214-3
... process. The basic cause of degradation was found to be hot corrosion caused by the deposition of alkali sulfates and chlorides. However this degradation may have been aggravated by thermal cycling and abrasion. The source of the salt was impurities in the flux. Two potential solutions were proposed...
Abstract
Grate bars in the traveling grate indurators in several taconite processing units suffered excessive corrosion following a conversion from acid to fluxed pellet production procedures. The campaign life of the HH grade cast stainless steel bars was reduced from more than 7 years to approximately 9 months. Several corroded grate bars were examined metallographically and by electron microscopy to determine the causes of the accelerated corrosion. Chemical and X-ray diffraction analyses were also conducted, along with simulation tests to assess the role of alkali chlorides in the corrosion process. The basic cause of degradation was found to be hot corrosion caused by the deposition of alkali sulfates and chlorides. However this degradation may have been aggravated by thermal cycling and abrasion. The source of the salt was impurities in the flux. Two potential solutions were proposed: modification of the processing parameters to reduce the salt deposition and / or change of bar materials to a more resistant alloy.
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Degradation of rupture for Udimet 500 due to hot corrosion at 705 °C (1300 ...
Available to PurchasePublished: 01 January 2002
Image
Hot corrosion attack of René 77 nickel-base alloy turbine blades. (a) Land-...
Available to Purchase
in Elevated-Temperature Life Assessment for Turbine Components, Piping, and Tubing
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 11 Hot corrosion attack of René 77 nickel-base alloy turbine blades. (a) Land-based, first-stage turbine blade. Notice deposit buildup, flaking, and splitting of leading edge. (b) Stationary vanes. (c) A land-based, first-stage gas turbine blade that had type 2 hot corrosion attack. (d
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(a) Type I hot corrosion at a blade tip IN-738 alloy. Note the subsurface s...
Available to PurchasePublished: 30 August 2021
Fig. 21 (a) Type I hot corrosion at a blade tip IN-738 alloy. Note the subsurface sulfides (arrows). (b) Type II hot corrosion attack of a blade shank (below the platform) CMSX-4 (single-crystal) alloy. The sample was etched with Marble’s reagent to show the lack of alloy depletion under
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Micrographs of grate bar that suffered hot corrosion. (a) Unetched, showing...
Available to Purchase
in Hot Corrosion of Stainless Steel Grate Bars in Taconite Indurators
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 3 Micrographs of grate bar that suffered hot corrosion. (a) Unetched, showing external oxide scale and internal sulfide particles (light gray area). (b) Etched, showing external oxide scale along with precipitated carbides (dark gray area)and lamellar structure consisting of austenite
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Results of laboratory hot corrosion (cyclic) tests on HH steel coupons for ...
Available to Purchase
in Hot Corrosion of Stainless Steel Grate Bars in Taconite Indurators
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 6 Results of laboratory hot corrosion (cyclic) tests on HH steel coupons for 100h. (a) and (b) Coupons corroded undersulfate and sulfate-chloride loading, respectively (c) and (d) Corrosion morphology undersulfate and sulfate-chloride loading, respectively.
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Effect of molten salt on hot corrosion at 700 °C (1290 °F) in air. With the...
Available to PurchasePublished: 15 January 2021
Fig. 23 Effect of molten salt on hot corrosion at 700 °C (1290 °F) in air. With the lower melting temperatures of salt mixtures, the corrosion rate increases with increasing volume fraction of liquid. Courtesy of Z. Tang and B. Gleeson, University of Pittsburgh
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in Failure Analysis of Gas Turbine Last Stage Bucket Made of Udimet 500 Superalloy
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Image
Degradation of rupture for Udimet 500 due to hot corrosion at 705 °C (1300 ...
Available to Purchase
in Failure of Gas Turbine Last- Stage Bucket
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Image
Macrograph showing the hot corrosion cavities found on the SS of the bucket...
Available to Purchase
in Corrosion Failures in Gas Turbine Hot Components
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Book Chapter
Corrosion Failures in Gas Turbine Hot Components
Available to PurchaseSeries: 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
... 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...
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.
Book Chapter
Corrosion of Steel Pipes in a Closed-Loop Hot Water Heating System
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c9001701
EISBN: 978-1-62708-219-8
... Biological corrosion A closed-loop hot water heating system at a museum in South Carolina was the subject of this failure evaluation. The system consisted of plain carbon steel pipes (Schedule 40) made of ASTM A 106 or A 53 (ERW or Seamless). The supply and return lines were made of the same materials...
Abstract
A closed-loop hot water heating system at a museum in South Carolina was the subject of failure evaluation. The system consisted of plain carbon steel pipes (Schedule 40) made of ASTM A 106 or A 53 (ERW or seamless). The supply and return lines were made of the same materials. The fittings were mechanically threaded assemblies. Temperatures ranged from 150 to 155 deg F (65.6 to 68.3 deg C). Leaks in the system had reportedly initiated immediately after the building had been placed in service. The cause of corrosion inside the steel pipes was attributed to tuberculation caused by oxygen concentration cells and oxygen-pitting related corrosion. Both types of corrosion are due to the poor quality of the water and the lack of corrosion control in the water system.
Book Chapter
Failure Analysis of Gas Turbine Last Stage Bucket Made of Udimet 500 Superalloy
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001602
EISBN: 978-1-62708-229-7
... Abstract This article presents a failure analysis of 37.5 mW gas turbine third stage buckets made of Udimet 500 superalloy. The buckets experienced repetitive integral tip shroud fractures assisted by a low temperature (type II) hot corrosion. A detailed analysis was carried out on elements...
Abstract
This article presents a failure analysis of 37.5 mW gas turbine third stage buckets made of Udimet 500 superalloy. The buckets experienced repetitive integral tip shroud fractures assisted by a low temperature (type II) hot corrosion. A detailed analysis was carried out on elements thought to have influenced the failure process: a) the stress increase from the loss of a load bearing cross-sectional area of the bucket tip shroud by the conversion of metal to the corrosion product (scale), b) influence of the tip shroud microstructure (e.g., a presence of equiaxed and columnar grains, their distribution and orientation), c) evidence of the transgranular initiation, and d) intergranular creep mechanism propagation. The most probable cause of the bucket damage was the combination of increased stresses due to corrosion-induced thinning of the tip shroud and unfavorable microstructures in the tip shroud region.
Book Chapter
Premature Failure of Turbine Blades by Corrosion
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c0046969
EISBN: 978-1-62708-227-3
..., 2.7x micrographic examination on sections etched with ferric chloride and hydrochloric acid in methanol) supported the conclusions that the blades failed by hot-corrosion attack. Variation in rate of attack on coated blades was attributed to variation in integrity of the aluminide coating, which had...
Abstract
Aluminide-coated and uncoated IN-713 turbine blades were returned for evaluation after service in a marine environment because of severe corrosion. Based on service time, failure of these blades by corrosive deterioration was considered to be premature. Analysis (visual inspection, 2.7x micrographic examination on sections etched with ferric chloride and hydrochloric acid in methanol) supported the conclusions that the blades failed by hot-corrosion attack. Variation in rate of attack on coated blades was attributed to variation in integrity of the aluminide coating, which had been applied in 1966, when these coatings were relatively new. It is evident that maintaining the integrity of a protective coating could significantly increase the life of a nickel-base alloy blade operating in a hot and corrosive environment.
Book Chapter
High-Temperature Corrosion-Related Failures
Available to PurchaseSeries: 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
... 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...
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.
Book Chapter
High-Temperature Corrosion-Related Failures
Available to PurchaseSeries: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006787
EISBN: 978-1-62708-295-2
... 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...
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
Corrosive Attack of Stainless Steel Welds in Hot Brine
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c0047606
EISBN: 978-1-62708-228-0
..., the substitution of a more corrosion-resistant alloy, such as Incoloy 800 or 825, may be necessary. Activation Butt welds Pipes Residual stress Weld metal 316L UNS S31603 Stress-corrosion cracking Pitting corrosion Joining-related failures Type 316L stainless steel pipes carrying brine at 120...
Abstract
Type 316L stainless steel pipes carrying brine at 120 deg C (250 deg F) and at a pH of about 7, failed by perforation at or near circumferential butt-weld seams. The failure was examined optically and radiographically in the field. Specimens were removed and examined metallographically and with a SEM in the laboratory. The examinations revealed a combination of failure mechanisms. The pitting failure of the welds was attributed to localized attack of an activated surface, in which anodic pits corroded rapidly. Additionally, SCC driven by residual welding stresses occurred in the base metal adjacent to the welds. Use of highly stressed austenitic stainless steels in high-chloride environments having a temperature above 65 deg C (150 deg F) should be discouraged. Solution annealing or shot peening to reduce residual stresses may be advisable. If heat treatment is not feasible after welding, the substitution of a more corrosion-resistant alloy, such as Incoloy 800 or 825, may be necessary.
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Schematic diagram of shipboard engine corrosion rates of type I and type II...
Available to PurchasePublished: 15 January 2021
Fig. 22 Schematic diagram of shipboard engine corrosion rates of type I and type II hot corrosion versus temperature in a marine environment compared with the Arrhenius oxidation rate versus temperature. LTHC, low-temperature hot corrosion; HTHC, high-temperature hot corrosion. Courtesy of U.S
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