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microstructural defects
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in Failures Due to Lack of Quality Control or Improper Quality Control
> Failure Investigation of Boiler Tubes: A Comprehensive Approach
Published: 01 December 2018
Fig. 6.166 Microstructural defects in weld, (a) 200×, (b) 100×, (c) 200×. (d) Microstructure of the weld, 100×. (e) Microstructure of outer surface near weld, 200×. (f) Puncture contours showing corrosion damage, 200×
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Published: 01 December 2000
Fig. 4.7 Representative microstructural defects in titanium alloys. (a) Type I alpha segregation; large voids surrounded by stabilized alpha. (b) Type I alpha segregation; small voids surrounded by stabilized alpha. (c) Type II alpha segregation as revealed by an etch-anodized technique. (d
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Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430351
EISBN: 978-1-62708-253-2
.... The parent metal microstructure was banded ferrite-pearlite, a normal microstructure for the tube. The weld microstructure consisted of dendritic ferrite and fine carbides. The weld region showed multiple types of defect such as porosity, undercut, and lack of fusion at the weld interpass ( Fig. 6.166a...
Abstract
Boiler tube failures associated with material defects are often the result of poor quality control, whether in primary production, on-site fabrication, storage and handling, or installation. This chapter examines quality-related failures stemming from compositional and structural defects, forming and welding defects, design defects, improper cleaning methods, and ineffective maintenance. It also includes case studies and illustrations.
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Published: 01 August 2015
cracking is aided by inclusion defects. 2% nital. 200×. (g) SAE 1144 steel as quenched and tempered; microstructure is tempered martensite where cracking is aided by inclusion defects. Unetched. 100×.
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2015
DOI: 10.31399/asm.tb.piht2.t55050175
EISBN: 978-1-62708-311-9
... by inclusion defects. 2% nital. 200×. (g) SAE 1144 steel as quenched and tempered; microstructure is tempered martensite where cracking is aided by inclusion defects. Unetched. 100×. Fig. 9.14 (Part 3) Micrographs of cracks. (h) SAE 8630 steel as quenched; microstructure is martensite where cracking...
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 1997
DOI: 10.31399/asm.tb.wip.t65930039
EISBN: 978-1-62708-359-1
... reinforcement is left intact. The goal of this test is to verify that overload failure will occur in the base metal rather than in the weld metal or HAZ. Ductility Ductility is another critical weld property. In addition to defects, many welding processes can produce hard, brittle microstructures...
Abstract
This article reviews nondestructive and destructive test methods used to characterize welds. The first process of characterization discussed involves information that may be obtained by direct visual inspection and measurement of the weld. An overview of nondestructive evaluation is included that encompasses techniques used to characterize the locations and structure of internal and surface defects, including radiography, ultrasonic testing, and liquid penetrant inspection. The next group of characterization procedures discussed is destructive tests, requiring the removal of specimens from the weld. The third component of weld characterization is the measurement of mechanical and corrosion properties. Following the discussion on the characterization procedures, the second part of this article provides examples of how two particular welds were characterized according to these procedures.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2000
DOI: 10.31399/asm.tb.ttg2.t61120025
EISBN: 978-1-62708-269-3
... place by dissolution, which is effected by the higher superheat possible in cold-hearth melting compared to VAR. Fig. 4.7 Representative microstructural defects in titanium alloys. (a) Type I alpha segregation; large voids surrounded by stabilized alpha. (b) Type I alpha segregation; small voids...
Abstract
This chapter describes the basic steps in the production of titanium ingots and their subsequent conversion to standards product forms. It explains how titanium ore is reduced to a spongy residue, then granularized, compacted, and melted (along with alloying additions) to form an ingot, which may be remelted several times to achieve the necessary properties. It also discusses the cause of defects and ingot imperfections and the benefits of billet reduction and grain-refinement processes.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270087
EISBN: 978-1-62708-301-0
... of crack initiation could not be established, material defects, improper root loading, and high operating temperatures were ruled out. This chapter describes how investigators came to their conclusions and what they learned through visual and SEM examination and qualitative elemental analysis. It includes...
Abstract
A turbine blade in an aircraft engine failed, fracturing at the root above the fir tree region. Fractography indicated that a fatigue crack initiated at the trailing edge of the blade and the final fracture occurred when the crack reached critical length. Although the exact cause of crack initiation could not be established, material defects, improper root loading, and high operating temperatures were ruled out. This chapter describes how investigators came to their conclusions and what they learned through visual and SEM examination and qualitative elemental analysis. It includes images of the microstructure and fracture surfaces and explains what some of the details reveal about the failure.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2021
DOI: 10.31399/asm.tb.ciktmse.t56020001
EISBN: 978-1-62708-389-8
... and microstructural defects that make modern advanced materials possible. There are many cases when the addition of a second element to a given matrix results in the formation of a compound that then precipitates within the matrix, for example, the addition of carbon in iron to form Fe 3 C, the addition of Al...
Abstract
Alloying, heat treating, and work hardening are widely used to control material properties, and though they take different approaches, they all focus on imperfections of one type or other. This chapter provides readers with essential background on these material imperfections and their relevance in design and manufacturing. It begins with a review of compositional impurities, the physical arrangement of atoms in solid solution, and the factors that determine maximum solubility. It then describes different types of structural imperfections, including point, line, and planar defects, and how they respond to applied stresses and strains. The chapter makes extensive use of graphics to illustrate crystal lattice structures and related concepts such as vacancies and interstitial sites, ion migration, volume expansion, antisite defects, edge and screw dislocations, slip planes, twinning planes, and dislocation passage through precipitates. It also points out important structure-property correlations.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2015
DOI: 10.31399/asm.tb.piht2.t55050263
EISBN: 978-1-62708-311-9
... Abstract This chapter presents a step-by-step approach for analyzing the causes of nonconforming workpieces and determining potential solutions. The discussion covers a wide range of issues, including testing errors, latent and process-related defects, examination and testing techniques, defect...
Abstract
This chapter presents a step-by-step approach for analyzing the causes of nonconforming workpieces and determining potential solutions. The discussion covers a wide range of issues, including testing errors, latent and process-related defects, examination and testing techniques, defect characterization, and effective remedial actions.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 1997
DOI: 10.31399/asm.tb.wip.t65930003
EISBN: 978-1-62708-359-1
... controls the size and shape of grains, the extent of segregation, and the distribution of inclusions and defects such as porosity and hot cracks. Since the properties and integrity of the weld metal depend on the solidification behavior and the resulting microstructural characteristics, understanding weld...
Abstract
It is well established that solidification behavior in the fusion zone controls the size and shape of grains, the extent of segregation, and the distribution of inclusions and defects such as porosity and hot cracks. Since the properties and integrity of the weld metal depend on the solidification behavior and the resulting microstructural characteristics, understanding weld pool solidification behavior is essential. This article provides a general introduction of key welding variables including solidification of the weld metal or fusion zone and microstructure of the weld and heat-affected zone. It discusses the effects of welding on microstructure and the causes and remedies of common welding flaws.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 1997
DOI: 10.31399/asm.tb.wip.t65930071
EISBN: 978-1-62708-359-1
... and strain development should always be considered, as should optimizing weld joint design as discussed above. Hydrogen-Induced Cracking (Cold Cracking) Cold cracks are defects that form as the result of the contamination of the weld microstructure by hydrogen. Whereas solidification cracking and HAZ...
Abstract
The formation of defects in materials that have been fusion welded is a major concern in the design of welded assemblies. This article describes four types of defects that, in particular, have been the focus of much attention because of the magnitude of their impact on product quality. Colloquially, these four defect types are known as hot cracks, heat-affected zone microfissures, cold cracks, and lamellar tearing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140039
EISBN: 978-1-62708-335-5
... Abstract In castings, microstructural features are products of metal chemistry and solidification conditions. The microstructural features, excluding defects, that most strongly affect the mechanical properties or aluminum castings are size, form, and distribution of intermetallic phases...
Abstract
In castings, microstructural features are products of metal chemistry and solidification conditions. The microstructural features, excluding defects, that most strongly affect the mechanical properties or aluminum castings are size, form, and distribution of intermetallic phases; dendrite arm spacing; grain size and shape; and eutectic modification and primary phase refinement. This chapter discusses the effects of these microstructural features on properties and methods for controlling them. The chapter concludes with a detailed examination of the refinement of hypereutectic aluminum-silicon alloys.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320103
EISBN: 978-1-62708-332-4
.... casting defects chemical composition gating gray iron iron castings mechanical properties microstructure pouring rate slag entrainment stress relieving white cast iron GRAY IRON, one of the earliest cast metals discovered, has been the most widely used cast material over the centuries. Its...
Abstract
This chapter covers mechanical properties, microstructures, chemical compositions, manufacturing processes, and engineering of gating practices for several applications of gray, white, and alloyed cast irons. It begins with a description of material standards, followed by a section providing information on the practice of stress relieving. Next, the chapter details various ways of eliminating slag entrainment while designing gating and venting systems. Several factors related to the establishment of the optimum pouring rate and time are then covered. Further, the chapter discusses the technology of unalloyed or low-alloyed gray iron castings and white iron and high-alloyed cast irons. Finally, it describes the casting defects that are associated with cast iron and the processes involved in solving these defects. The article includes a number of figures illustrating the topics discussed.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2006
DOI: 10.31399/asm.tb.ex2.t69980141
EISBN: 978-1-62708-342-3
... of the continuous cast microstructure of aluminum and copper alloys. The discussion provides information on billet and grain segregation and defects in continuous casting. The chapter then discusses the processes involved in the deformation of pure metals and alloys at room temperature. Next, it describes...
Abstract
This chapter explains the basic terminology and principles of metallurgy as they apply to extrusion. It begins with an overview of crystal structure in metals and alloys, including crystal defects and orientation. This is followed by sections discussing the development of the continuous cast microstructure of aluminum and copper alloys. The discussion provides information on billet and grain segregation and defects in continuous casting. The chapter then discusses the processes involved in the deformation of pure metals and alloys at room temperature. Next, it describes the characteristics of pure metals and alloys at higher temperatures. The processes involved in extrusion are then covered. The chapter provides details on how the toughness and fracture characteristics of metals and alloys affect the extrusion process. The weld seams in hollow profiles, the production of composite profiles, and the processing of composite materials, as well as the extrusion of metal powders, are discussed. The chapter ends with a discussion on the factors that define the extrudability of metallic materials and how these attributes are characterized.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2008
DOI: 10.31399/asm.tb.fahtsc.t51130255
EISBN: 978-1-62708-284-6
... are dependent on the microstructural products that are present in steel. Typically, the first step in the transformation process is to heat the steel to its austenitizing temperature. The austenitized steel is then cooled rapidly to avoid the formation of pearlite, which is a relatively soft transformation...
Abstract
This chapter provides an overview of the fundamental material- and process-related parameters of quenching on residual stress, distortion control, and cracking. It begins with a description of phase transformations during heating and quenching of steel. This is followed by a section on the effects of materials and quench process design on distortion of steel during heat treating. Details on stress raisers and their role in quench cracking are then presented. The chapter ends with various selected case histories of failures attributed to the quenching process.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040193
EISBN: 978-1-62708-300-3
..., and the microstructure of the forging. 16.5.1 Metal Flow The information on metal flow is very important for die design. Improper metal flow produces defects in the forging. In real closed-die forging, it is necessary to wait until the forging is finished to see the forged part and the defect, if there is one...
Abstract
This chapter discusses the use of finite-element modeling in forging design. It describes key modeling parameters and inputs, mesh generation and computation time, and process modeling outputs such as metal flow, strain rate, loading profiles, and microstructure. It also includes a variety of application examples.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430027
EISBN: 978-1-62708-253-2
... stainless steels heat treatment isothermal transformation microstructural defects steels superalloys 3.1 Introduction Materials used for different engineering applications are broadly classified as metallic materials (i.e., metals and alloys), ceramics, or plastics and polymers. The combination...
Abstract
This chapter describes the metallurgy, composition, and properties of steels and other alloys. It provides information on the atomic structure of metals, the nature of alloy phases, and the mechanisms involved in phase transformations, including time-temperature effects and the role of diffusion, nucleation, and growth. It also discusses alloying, heat treating, and defect formation and briefly covers condenser tube materials.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290099
EISBN: 978-1-62708-306-5
.... Hydrogen-Induced Cracking (Cold Cracking) Cold cracks are defects that form as the result of the contamination of the weld microstructure by hydrogen. Whereas solidification cracking and HAZ cracking occur during or soon after the actual welding process, hydrogen-induced cracking is usually a delayed...
Abstract
During fusion welding, the thermal cycles produced by the moving heat source causes physical state changes, metallurgical phase transformations, and transient thermal stresses and metal movement. This chapter begins by discussing weld metal solidification behavior and the solid-state transformations of the main classes of metals and alloys during fusion welding. The main classes include work- or strain-hardened metals and alloys, precipitation-hardened alloys, transformation-hardened steels and cast irons, stainless steels, and solid-solution and dispersion-hardened alloys. The following section provides information on the residual stresses and distortion that remain after welding. The focus then shifts to distortion control of weldments. Inclusions and cracking are discussed in detail. The chapter also discusses the causes for reduced fatigue strength of a component by a weld: stress concentration due to weld shape and joint geometry; stress concentration due to weld imperfections; and residual welding stresses. Inspection and characterization of welds are described in the final section of this chapter.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 31 December 2020
DOI: 10.31399/asm.tb.phtbp.t59310001
EISBN: 978-1-62708-326-3
...-packed, and body-centered cubic. It then describes the four main divisions of crystal defects, namely point defects, line defects, planar defects, and volume defects. The chapter provides information on grain boundaries of metals, processes involved in atomic diffusion, and key properties of a solid...
Abstract
The building block of all matter, including metals, is the atom. This chapter initially provides information on atomic bonding and the crystal structure of metals and alloys, followed by a description of three crystal lattice structures of metals: face-centered cubic, hexagonal close-packed, and body-centered cubic. It then describes the four main divisions of crystal defects, namely point defects, line defects, planar defects, and volume defects. The chapter provides information on grain boundaries of metals, processes involved in atomic diffusion, and key properties of a solid solution. It also explains the aspects of a phase diagram that shows what phase or phases are present in the alloy under conditions of thermal equilibrium. Finally, a discussion on the applications of equilibrium phase diagrams is presented.