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oxidation
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001738
EISBN: 978-1-62708-220-4
... showed that the cracking could not be caused by creep. It was found that the cracking was confined to a 4-mm deep coarse-grained zone (ASTM 0-1) at the outer diameter. The cracking appeared to be caused by strain-induced intergranular oxidation. When the cracks reached the fine-grained material...
Abstract
During a planned shut-down in 1990 it appeared that the bottom manifold parts made of wrought Incoloy 800H had undergone diametrical expansion of up to 2% due to creep. Further, cracking at the outer diam was found. It was decided to replace these parts. Microscopical investigations showed that the cracking could not be caused by creep. It was found that the cracking was confined to a 4-mm deep coarse-grained zone (ASTM 0-1) at the outer diameter. The cracking appeared to be caused by strain-induced intergranular oxidation. When the cracks reached the fine-grained material, the oxidation-cracks stopped. To determine the residual creep life of the sound (non-cracked) bottom manifold material, iso-stress creep tests were performed. It was found that tertiary creep started at 7% strain. The time-to-rupture was greater than 100,000 h. It was concluded that the bottom manifold (and thus the furnace) could be used safely during the foreseen production period.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0090114
EISBN: 978-1-62708-229-7
... holes' surface was not coated. Investigation supported the conclusions that the cracking at the cooling holes was due to grain-boundary oxidation and nitridation at the cooling hole surface, embrittlement and loss of local ductility of the base alloy, temperature gradient from the airfoil surface...
Abstract
The first-stage blades in a model 501D5 gas turbine had 16 cooling holes. After 32,000 h of service, the blades exhibited cracking at the cooling holes. The blade material was wrought Udimet 520 alloy, with nominal composition of 57Ni-19Cr-12Co-6Mo-1W-2Al-3Ti-0.05C-0.005B. The cooling holes' surface was not coated. Investigation supported the conclusions that the cracking at the cooling holes was due to grain-boundary oxidation and nitridation at the cooling hole surface, embrittlement and loss of local ductility of the base alloy, temperature gradient from the airfoil surface to the cooling holes, which led to relatively high thermal stresses at the holes located at the thicker sections of the airfoil, and stress concentration of 2.5 at the cooling hole and the presence of relatively high total strain (an inelastic strain of 1.2%) at the cooling hole surface. Recommendations include applying the specially designed methods given in this case study to estimate the metal temperature and stresses in order to predict the life of turbine blades under similar operating conditions.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0048257
EISBN: 978-1-62708-217-4
... and it was suggested that it had resulted from surface defects. A decarburized surface layer and subsurface oxidation in the vicinity of pitting were revealed by metallographic examination of the 2% nital etched gear tooth sample. It was concluded that pitting had resulted as a combination of both the defects...
Abstract
Evidence of destructive pitting on the gear teeth (AMS 6263 steel) in the area of the pitchline was exhibited by an idler gear for the generator drive of an aircraft engine following test-stand engine testing. The case hardness was investigated to be lower than specified and it was suggested that it had resulted from surface defects. A decarburized surface layer and subsurface oxidation in the vicinity of pitting were revealed by metallographic examination of the 2% nital etched gear tooth sample. It was concluded that pitting had resulted as a combination of both the defects. The causes for the defects were reported based on previous investigation of heat treatment facilities. Oxide layer was caused by inadequate purging of air before carburization while decarburization was attributed to defects in the copper plating applied to the gear for its protection during austenitizing in an exothermic atmosphere. It was recommended that steps be taken during heat treatment to ensure neither of the two occurred.
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in Oxidation Cracking and Residual Creep Life of an Incoloy 800H Bottom Manifold in a Steam Reformer at 800 °C
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 5 Oxidation and nitride formation along the crack sides and the crack tip. Magnification = 100 ×
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Published: 01 June 2019
Fig. 1 (a) Microstructure of tube that had suffered less oxidation; (b) microstructure of tube with more oxidation (external surface). Etched in 1% Nital.
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in Failure of an ASTM A681-89 H13 Die Segment for Die Casting of Aluminum
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 6 Oxidation at the surface of the segment. Unetched. 620×.
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in Cracking of Inconel 800H in a Steam Methane Reformer Furnace
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 4 Photomicrograph showing intergranular oxidation, grain boundary precipitates, and matrix stringers. 63×
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Published: 01 December 1993
Fig. 2 Tube 2 failure site a (see Fig. 1 ). Note the heavy oxidation and longitudinal secondary creep cracks. 0.60×
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Published: 01 December 1993
Fig. 3 Tube 1 failure site b (see Fig. 1 ). Note the heavy oxidation and longitudinal secondary creep cracks. 0.60×
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in “On-Load Corrosion” in Tubes of High Pressure Boilers
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 2 Severe oxidation of boiler tube to give uniform layer of crystalline magnetite
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in Evaluation of Gas Turbine Hot Section Blade Cracking under Oxidation, TMF, and Creep Conditions
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 2 Oxidation and cracking at cooling holes in a turbine blade. (a) Trailing edge cooling hole surface showing oxidation and nitridation attack on the surface after 32,000 h of operation. (b) Crack found on the surface of No. 5 cooling hole. Oxidation on the crack surface and hole surface
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in Failure of a Nickel-Base Alloy Incinerator Liner
> ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions
Published: 01 June 2019
Fig. 2 Incinerator environment has led to accelerated oxidation of the IN-690 liner approximately 100 to 150 μm deep. Oxidation first initiates along intergranular paths. Width represents approximately 0.572 mm (0.0225 in.)
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in Failure of High-Temperature Rotary Valve Due to Expansion and Distortion Caused by the Effects of Excessive Operating Temperature
> ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions
Published: 01 June 2019
Fig. 1 Oxidation and thermal fatigue cracking of a cast ductile iron rotor. See also Fig. 2 , 3 , 4 , 5 , 6 , and .
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in Fatigue and Corrosion Fatigue Failure Surfaces of Concrete Reinforcement
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
Fig. 2 Electron image showing bright metal (left), oxidation products (right) and the commencement of oxidation development on the surface of the metal. Right - X-ray image showing Cl concentration in the oxidation product and in spots where the metal is actively corroding.
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in Investigation on Bulging of Blow Pipe in a Blast Furnace
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 4 SEM micrograph showing surface and grain boundary oxidation
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Published: 01 December 2019
Fig. 3 Sample 1 (away from fracture/severe oxidation in the whole section of the tube). Outer wall. Microstructure: ferrite and pearlite
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Published: 01 December 2019
Fig. 4 Sample 2 (region of fracture/not severe oxidation). Outer wall of the side which was not exposed to hot gas flux. Microstructure: ferrite and pearlite
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Published: 01 December 2019
Fig. 9 Sample 3 (area near the fracture/severe oxidation): inner wall on the side of exposure to the hot gas flux. Microstructure: martensite, bainite, and ferrite with carbide precipitation
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in High-Temperature Stress Relaxation Cracking and Stress Rupture Observed in a Coke Gasifier Failure
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 20 Photomicrograph of the cracks and oxidation on the outside surface of the dip tube
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in Failure Analysis of Fire Tube Sleeve of Heater Treater
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 9 Microstructure of damaged sleeve showing severe oxidation of metal plate at the edge, 100×
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