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Oxidized Recuperator Pipes 氧化回热管
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c9001233
F. Naumann, F. Spies
{"title":"Oxidized Recuperator Pipes","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.steel.c9001233","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c9001233","url":null,"abstract":"\u0000 High-chromium steel pipes 42.25 x 3.25 mm from a blast furnace gas fired recuperator for the preheating of air were heavily oxidized and perforated in places. It was found that the blast furnace gas had a high sulfur content. Both the carburization and the formation of sulfide proved that in addition, from time to time at least, combustion was incomplete and the operation was carried out in a reducing atmosphere, with the result that oxygen deficiency prevented the formation or maintenance of a protective surface layer on the external surface of the pipes. The sulfur would probably not have damaged the nickel-free steel used here at the given temperatures if it had been present as sulfur dioxide in an oxidizing atmosphere. The damage was therefore caused primarily by an incorrectly conducted combustion process.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"69 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115307608","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of Recuperator with Austenitically Welded Pipes 奥氏体焊管回热器故障
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c9001159
F. Naumann, F. Spies
{"title":"Failure of Recuperator with Austenitically Welded Pipes","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.steel.c9001159","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c9001159","url":null,"abstract":"\u0000 A recuperator used for preheating the combustion air for a rolling mill furnace failed after a relatively short service time because of leakage of the pipes in the colder part. The 6 % chrome steel pipes used for the warmer part connected by means of welding with austenitic electrodes to the unalloyed mild steel pipe of larger diam. Visual inspection showed corrosion and deep, trench-like erosion over the entire circumference of the seam on the side of the thicker mild steel pipe. Examination using the V2-A solution for picral etch showed the microstructure of the unalloyed pipe had become coarse-grained and acicular, and the microstructure of the welding seam had become predominantly martensitic as a result of the mixing of the weld metal with the fused pipe material. The chrome steel pipe had become partially transformed to martensite or bainite at the transition to the weld. Thus, the failure occurred due to typical contact corrosion wherein the alloyed welding seam represented the less noble electrode. The martensitic structure may have contributed to the failure as well. Due to the typical nature of the failure, no recommendations were made.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"16 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125687520","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of Radiant Tubes in a Batch-Carburizing Furnace 批量渗碳炉辐射管故障
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c0046995
{"title":"Failure of Radiant Tubes in a Batch-Carburizing Furnace","authors":"","doi":"10.31399/asm.fach.steel.c0046995","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c0046995","url":null,"abstract":"\u0000 Three radiant tubes, made of three different high-temperature alloys, were removed from a carburizing furnace after approximately eight months of service when they showed evidence of failure by collapsing (telescoping) in a region 30 cm (12 in.) from the tube bottoms in the vicinity of the burners. The tubes had an original wall thickness of 3.0 mm (0.120 in.) and were made of three different alloys: the first was Hastelloy X; the second alloy was RA 333, a wrought nickel-base heat-resistant alloy; and the third was experimental alloy 634, which contained 72% Ni, 4% Cr, and 3.5% Si. The three radiant tubes had been operated at a temperature of about 1040 deg C (1900 deg F) to maintain furnace temperatures of 900 to 925 deg C (1650 to 1700 deg F). Analysis (visual inspection and micrographic examination) supported the conclusion that all three tubes failed by corrosion. Recommendations included replacing the material with an alloy, such as RA 333, with a higher chromium content and with an additional element, like silicon, resistant to carburization-oxidation.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132290085","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Identification of Iron Oxide Inclusions 氧化铁夹杂物的鉴定
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c0045909
{"title":"Identification of Iron Oxide Inclusions","authors":"","doi":"10.31399/asm.fach.steel.c0045909","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c0045909","url":null,"abstract":"\u0000 A hot rolled, low-carbon steel pot used to melt magnesium alloys leaked, releasing about 35 kg (80 lb) of molten magnesium onto the foundry floor and causing an extensive fire. Due to the fire, the original leakage hole could not be investigated. Samples of the failed pot were polished and etched and were found to be composed of ferrite and pearlite mixtures, as would be expected. However, the sample taken from a location about 75 mm (3 in.) from the hole contained a cluster of unusually large inclusions. By removing the beryllium window from in front of the detector, EPMA spectra were obtained from the inclusions and from the steel matrix. The inclusion spectrum contained primarily iron and oxygen, whereas the matrix spectrum contained primarily iron. X-ray maps were made to show the distribution of iron and oxygen. These results indicated that the inclusions were iron oxide. A similar inclusion at the failure site in the melting pot may have reacted violently with the molten magnesium, causing the leak.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"48 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133084621","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Perforation of a Nickel-Base Alloy Kiln 镍基合金窑的穿孔
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c0091757
{"title":"Perforation of a Nickel-Base Alloy Kiln","authors":"","doi":"10.31399/asm.fach.steel.c0091757","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c0091757","url":null,"abstract":"\u0000 A kiln, 7.6 m (25 ft) long with a 1 m (3 ft) internal diameter and a 6.3 mm (0.25 in.) wall thickness, is used to regenerate spent charcoal returned by water utilities. This charcoal contains up to 0.57% S and 2.04% Cl. The kiln is made of Inconel 601 (N06601) welded using Inconel 617 (N06617) as a filler alloy. Wet charcoal is fed in at one end of the kiln and travels while being tumbled within the inclined rotating vessel. Temperatures range from 480 deg C (900 deg F) (Zone 1) to 900 deg C (1650 deg F) (Zones 2 and 3). Steam is introduced at the discharge end at 95 g/s (750 lb/h), 34 to 69 kPa (5 to 10 psi), and 125 deg C (260 deg F). The kiln developed perforations within eight months of operation. Investigation (visual inspection, metallurgical analysis, energy-dispersive spectroscopy, and 44X micrographs) supported the conclusion that the sulfur and chlorine in the charcoal attacked the Inconel 601, forming various sulfides and chlorides. Recommendations included on-site testing, and installation of test coupons of various alloys before fabricating another kiln. The suggested alloys were RA85H, 800HT, HR-120, Haynes 556, and HR-160.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115937744","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Low Cycle Thermal Fatigue and Fracture of Reinforced Piping 增强管的低周热疲劳与断裂
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c9001149
W. J. O’Donnell, J. M. Watson, W. Mallin, J. Kenrick
{"title":"Low Cycle Thermal Fatigue and Fracture of Reinforced Piping","authors":"W. J. O’Donnell, J. M. Watson, W. Mallin, J. Kenrick","doi":"10.31399/asm.fach.steel.c9001149","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c9001149","url":null,"abstract":"\u0000 A large diameter steel pipe reinforced by stiffening rings with saddle supports was subjected to thermal cycling as the system was started up, operated, and shut down. The pipe functioned as an emission control exhaust duct from a furnace and was designed originally using lengths of rolled and welded COR-TEN steel plate butt welded together on site. The pipe sustained local buckling and cracking, then fractured during the first five months of operation. Failure was due to low cycle fatigue and fast fracture caused by differential thermal expansion stresses. Thermal lag between the stiffening rings welded to the outside of the pipe and the pipe wall itself resulted in large radial and axial thermal stresses at the welds. Redundant tied down saddle supports in each segment of pipe between expansion joints restrained pipe arching due to circumferential temperature variations, producing large axial thermal bending stresses. Thermal cycling of the system initiated fatigue cracks at the stiffener rings. When the critical crack size was reached, fast fracture occurred. The system was redesigned by eliminating the redundant restraints and by modifying the stiffener rings to permit free radial thermal breathing of the pipe.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"13 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116829072","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Premature Failure of a Type 309 Stainless Steel Pan for a Lead Bath 用于铅浴的309型不锈钢锅过早失效
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c0046915
{"title":"Premature Failure of a Type 309 Stainless Steel Pan for a Lead Bath","authors":"","doi":"10.31399/asm.fach.steel.c0046915","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c0046915","url":null,"abstract":"\u0000 Severely reduced wall thickness was encountered at the liquid line of a lead-bath pan that was used in a continuous strip or wire oil-tempering unit. Replacement of the pan was necessary after six months of service. The pan, 6.9 m (22.5 ft) long, 0.6 m (2 ft) wide, and 38 cm (15 in.) deep with a 2.5-cm (1-in.) wall thickness, was a type 309 stainless steel weldment. Operating temperatures of the lead bath in the pan ranged from 805 deg C (1480 deg F) at the entry end to 845 deg C (1550 deg F) at the exit end. Analysis (visual inspection. metallographic analysis, moisture testing, and etched micrographs using Murakami's reagent) supported the conclusions that thinning of the pan walls at the surface of the molten lead resulted from using coke of high moisture content and from the low fluctuating coke level. Recommendations included reducing the supply of oxygen attacking the grain boundaries and the hydrogen that readily promoted decarburization with the use of dry (2 to 3% moisture content) coke. Maintaining a thick layer of coke over the entire surface of molten lead in the pan would exclude atmospheric oxygen from the grain boundaries.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131683778","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of Steel Rolling Mill Taper Bearing 轧钢机锥度轴承失效
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c9001513
H. Walton
{"title":"Failure of Steel Rolling Mill Taper Bearing","authors":"H. Walton","doi":"10.31399/asm.fach.steel.c9001513","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c9001513","url":null,"abstract":"\u0000 While in the stationary mode, capillary action at the contact line between roller and race in a steel rolling mill taper bearing caused a concentration of lubricant and moisture to occur. This lead to lines of corrosion pits at roller intervals. During subsequent operation, the individual corrosion pits acted as stress raisers and initiated coarse grain spalling. Due to a bending moment on the rotating element, this in turn initiated bending fatigue normal to the longitudinal axis, which propagated through to the bore of the inner ring. Stain marks were visible in the bore at a spacing corresponding to roller intervals where lubricant had flowed through the cracks from the race.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133672744","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Fatigue Fracture of a Cast Chromium-Molybdenum Steel Pinion 铸造铬钼钢小齿轮的疲劳断裂
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c0047406
{"title":"Fatigue Fracture of a Cast Chromium-Molybdenum Steel Pinion","authors":"","doi":"10.31399/asm.fach.steel.c0047406","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c0047406","url":null,"abstract":"\u0000 A cast countershaft pinion on a car puller for a blast furnace broke after one month of service; expected life was 12 months. The pinion was specified to be made of 1045 steel heat treated to a hardness of 245 HRB. The pinion steel was analyzed and was a satisfactory alternative to 1045 steel. The pinion was annealed before flame or induction hardening of the teeth to a surface hardness of 363 HRB and a core hardness of 197 HRB. The broken pinion had a tooth which had failed by fatigue fracture through the tooth root because of the low strength from incomplete surface hardening of the tooth surfaces. Contributing factors included uneven loading because of misalignment and stress concentrations in the tooth roots caused by tool marks. Greater strength was provided by oil quenching and tempering the replacement pinions to a hardness of 255 to 302 HRB. Machining of the tooth roots was revised to eliminate all tool marks. Surface hardening was applied to all tooth surfaces, including the root. Proper alignment of the pinion was ensured by carefully checking the meshing of the teeth at startup.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121674749","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Broken Back up Rolls from a Broad Strip Mill 宽带钢轧机的断背辊
ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.steel.c9001255
F. Naumann, F. Spies
{"title":"Broken Back up Rolls from a Broad Strip Mill","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.steel.c9001255","DOIUrl":"https://doi.org/10.31399/asm.fach.steel.c9001255","url":null,"abstract":"\u0000 Several back up rolls of 1400 mm barrel diam from a broad strip mill broke after a relatively short operating time as a result of bending stresses when the rolls were dismantled. The fracture occurred in the conical region of the neck at about 600 mm diam. The rolls were shaped steel castings with 0.8 to 1.0% C, 1% Mn, 1% Cr, 0.5% Mo and 0.4% Ni and were heat treated to a tensile strength of 950 N/sq mm. Because the bending stress on mounting was only 42 N/sq mm in the fracture cross section, it was evident at the outset that material defects had promoted the fracture. In the case of this roll and the other broken rolls, the cracking and fracture were promoted by various casting defects. Investigation of the rolls showed that both the breaking off of the neck and the disintegration of the barrel edges was caused by material defects, more exactly casting defects. The fractures on the other rolls examined were so badly rusted or contaminated that they were incapable of yielding any information.","PeriodicalId":226544,"journal":{"name":"ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment","volume":"112 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130738358","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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