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Use of Ultrasonic Inspection to Detect Creep Rupture in Stainless Steel Headers of an Ammonia-Plant Reformer Furnace 用超声波检测氨装置重整炉不锈钢集管蠕变破裂
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0060154
{"title":"Use of Ultrasonic Inspection to Detect Creep Rupture in Stainless Steel Headers of an Ammonia-Plant Reformer Furnace","authors":"","doi":"10.31399/asm.fach.modes.c0060154","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c0060154","url":null,"abstract":"\u0000 One of the coils in the radiant section of a primary reformer furnace used in an ammonia plant was found leaking. The bottom of one of seven outlet headers (made of ASME SA-452, grade TP316H, stainless steel) was revealed during examination to be ruptured. It was revealed by metallurgical examination that it had failed as a result of intergranular fissuring and oxidation (creep rupture). The ruptured area revealed that the header had failed by conventional long-time creep rupture as a result of exposure to operating temperatures probably between 900 and 955 deg C. Three samples from different sections (ruptured area, slightly bulged but nonruptured area and visually sound metal) were inspected. The presence of pinhead-size intergranular fissures throughout the cross sections of the latter two samples was observed. An ultrasonic attenuation method was employed to investigate the remaining headers. All headers were revealed by ultrasonic readings to be in an advanced stage of creep rupture and no areas were found to be fissured to a degree that they needed immediate replacement. As a conclusion, the furnace was deemed serviceable and it was established that in the absence of local hot spots, the headers would survive for a reasonable period of time.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"83 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":"132233631","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
Rupture of Low-Carbon Steel Boiler Tubes Because of Severe Overheating 低碳钢锅炉管因严重过热而破裂
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0048289
{"title":"Rupture of Low-Carbon Steel Boiler Tubes Because of Severe Overheating","authors":"","doi":"10.31399/asm.fach.modes.c0048289","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c0048289","url":null,"abstract":"\u0000 The center portions of two adjacent low-carbon steel boiler tubes (made to ASME SA-192 specifications) ruptured during a start-up period after seven months in service. It was indicated by reports that there had been sufficient water in the boiler two hours before start-up. The microstructure near the rupture edge was revealed by metallographic examination to consist of ferrite and acicular martensite or bainite. The microstructure and the observed lack of cold work indicated a temperature above the transformation temperature of 727 deg C had been reached. Swelling of the tubes was disclosed by the wall thickness and OD of the tubing. The tubes were concluded to have failed due to rapid overheating.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"14 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":"131077291","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
Corrosion of Steel Pipe in a Heating and Cooling System 加热和冷却系统中钢管的腐蚀
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001699
A.H. Khan
{"title":"Corrosion of Steel Pipe in a Heating and Cooling System","authors":"A.H. Khan","doi":"10.31399/asm.fach.modes.c9001699","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c9001699","url":null,"abstract":"\u0000 A shopping mall in South Carolina was originally constructed in 1988 and a second phase completed in 1989. The HVAC system inside the mall included an open, recirculating condenser water loop that served various fan coil units located within tenant spaces. The system had a recirculating capacity of about 44,000 gal (166,000 L) of water. It consisted primarily of steel pipes fitted with threaded connectors on the 2 in. (46 cm) pipes and bolted flanged couplings on the larger pipes. Seven years following the completion of the mall, corrosion problems were noted at the outer and inner surfaces of the pipe. Visual observations on the inner diametral surfaces revealed that the pipes were, in almost all cases, filled with corrosion products. A significant amount of base metal loss was documented in all of the samples. The cause of the observed corrosion was determined to be a lack of corrosion monitoring and poor water quality. Pipe replacement and a regular water testing program were recommended.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"1 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":"132951960","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
Cavitation Damage to Diesel Engine Cylinder Liners 柴油机缸套气蚀损伤
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001486
{"title":"Cavitation Damage to Diesel Engine Cylinder Liners","authors":"","doi":"10.31399/asm.fach.modes.c9001486","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c9001486","url":null,"abstract":"\u0000 Cavitation damage of diesel engine cylinder liners is due to vibration of the cylinder wall, initiated by slap of the piston under the combined forces of inertia and firing pressure as it passes top dead center. The occurrence on the anti-thrust side may possibly result from bouncing of the piston. The exact mechanism of cavitation damage is not entirely clear. Two schools of thought have developed, one supporting an essentially erosive, and the other an essentially corrosive, mechanism. Measures to prevent, or reduce, cavitation damage should be considered firstly from the aspect of design, attention being given to methods of reducing the amplitude of the liner vibration. Attempts have been made to reduce the severity of attack by attention to the environment. Inhibitors, such as chromates, benzoate/nitrite mixtures, and emulsified oils, have been tried with varying success. Attempts have been made to reduce or prevent cavitation damage by the application of cathodic protection, and this has been found to be effective in certain instances of trouble on propellers.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"99 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":"121140051","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
Steel Wire Cracked at Welded Joint 钢丝焊接接头开裂
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001186
F. Naumann, F. Spies
{"title":"Steel Wire Cracked at Welded Joint","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.modes.c9001186","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c9001186","url":null,"abstract":"\u0000 A 2.3 mm diam steel wire broke during cable twisting. The fracture occurred obliquely to the longitudinal axis of the wire and showed a constriction at the end. Therefore it was a ductile fracture. File mark type work defects were noticeable on the wire surface at both sides of the fracture, but they had no effect on the breakage of the wire. Away from the fracture area, the wire had a normal structure of hyperfine lamellar pearlite (sorbite) of a “patented” and cold drawn steel wire. In the vicinity of the fracture, the cementite of the pearlite was partially spheroidized, while at the fracture itself it was completely spheroidized. Therefore the wire was locally annealed at this point. It was likely that the wire cracked at this point during the last drawing and then broke during twisting due to its lower strength in the weakened cross section after prior deformation.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"1 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":"124227145","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
Stress-Corrosion Cracking of Copper Alloy C27000 Ferrules in Storage and in Service in Chemical Plants C27000铜合金卡箍在贮存和使用中的应力腐蚀开裂
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0091690
{"title":"Stress-Corrosion Cracking of Copper Alloy C27000 Ferrules in Storage and in Service in Chemical Plants","authors":"","doi":"10.31399/asm.fach.modes.c0091690","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c0091690","url":null,"abstract":"\u0000 A substantial number of copper alloy C27000 (yellow brass, 65Cu-35Zn) ferrules for electrical fuses cracked while in storage and while in service in paper mills and other chemical processing plants. The ferrules, made by three different manufacturers, were of several sizes. One commonly used ferrule was 3.5 cm long by 7.5 cm in diam and was drawn from 0.5 mm (0.020 in.) thick strip. Investigation (visual inspection, metallographic examination, and a mercurous nitrate test, which is an accelerated test used to detect residual stress in copper and copper alloys) of both ferrules from fuses in service and storage in different types of plants, and ferrules from newly manufactured fuses, supported the conclusion that the ferrules failed by SCC resulting from residual stresses induced during forming and the ambient atmospheres in the chemical plants. The atmosphere in the paper mills was the most detrimental, and the higher incidence of cracking of ferrules there was apparently related to a higher concentration of ammonia in conjunction with high humidity. Recommendations included specifying that the fuses meet the requirements of ASTM B 154.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"1 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":"122745067","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 Carburized Steel Impeller Drive Gears Due to Pitting and a Wear Pattern 渗碳钢叶轮传动齿轮因点蚀和磨损而失效
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0048253
{"title":"Failure of Carburized Steel Impeller Drive Gears Due to Pitting and a Wear Pattern","authors":"","doi":"10.31399/asm.fach.modes.c0048253","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c0048253","url":null,"abstract":"\u0000 Two intermediate impeller drive gears (made of AMS 6263 steel, gas carburized, hardened, and tempered) exhibited evidence of pitting and abnormal wear after production tests in test-stand engines. The gears were examined for hardness, case depth, and microstructure of case and core. It was found that gear 1 had a lower hardness than specified while the case hardness of gear 2 was found to be within limits. Both the pitting and the wear pattern were revealed to be more severe on gear 1 than on gear 2. Surface-contact fatigue (pitting) of gear 1 (cause of lower carbon content of the carburized case and hence lower hardness) was found to be the reason for failure. It was recommended that the depth of the carburized case on impeller drive gears be increased from 0.4 to 0.6 mm to 0.6 to 0.9 mm to improve load-carrying potential and wear resistance. A minimum case-hardness requirement was set at 81 HRA.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"50 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":"122867163","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 Failures, With Special Reference to Fracture Characteristics 疲劳失效，特别是断裂特性
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001459
G. A. Cottell
{"title":"Fatigue Failures, With Special Reference to Fracture Characteristics","authors":"G. A. Cottell","doi":"10.31399/asm.fach.modes.c9001459","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c9001459","url":null,"abstract":"\u0000 Fundamentals of fatigue failure are outlined. Addressed are fatigue crack characteristics, basic crack types, unidirectional bending, alternate bending, rotary bending, torsion, direct stress, and combined stress. Stress cycle, endurance limits, under and overstressing, stress concentration, and surface condition are discussed. Sections are devoted to fatigue crack assessment, corrosion relation to fatigue failure, and the micro-mechanisms of fatigue failure. Materials considered include steels. Photographs of service failures are used to illustrate features alluded to in the text.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","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":"114069907","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: 1
Destroyed Screen Bars of Stainless Steel 损坏的不锈钢筛网条
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001218
F. Naumann, F. Spies
{"title":"Destroyed Screen Bars of Stainless Steel","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.modes.c9001218","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c9001218","url":null,"abstract":"\u0000 Screens made of stainless steel X5 Cr-Ni-Mo 18 10 (Material No. 1.4401), which were exposed to cooling water from the mouth of a river, became unserviceable after a few months because of the breaking out of parts of the bars. The multiple fracturing of the screen bars in the brackish water of the mouth of the river was attributed to stress corrosion and pitting. The steel used, which contained molybdenum, would have withstood the severe corrosive conditions in the heat-treated condition, i.e. quenched after high temperature anneal. However, the stresses caused by deformation and welding, as well as the intensification of corrosive conditions brought about by design, i.e. creation of corrosion currents in the poorly aerated gaps (Evans elements), made this impossible.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","volume":"10 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":"124293442","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 Carbon Steel Counterbalance Spring Caused by Hydrogen Damage 碳钢平衡弹簧氢损伤致疲劳断裂
ASM Failure Analysis Case Histories: Failure Modes and Mechanisms Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0048147
{"title":"Fatigue Fracture of a Carbon Steel Counterbalance Spring Caused by Hydrogen Damage","authors":"","doi":"10.31399/asm.fach.modes.c0048147","DOIUrl":"https://doi.org/10.31399/asm.fach.modes.c0048147","url":null,"abstract":"\u0000 The power-type counterbalance spring, formed from hardened-and-tempered carbon steel strip and subsequently subjected to phosphating treatment, fractured at the two locations during fatigue testing. A rust colored dark band at the inside edge of the fracture surface was disclosed during investigation. Etch pits were revealed by the cleaned surface which were never observed on properly phosphated coating. It was interpreted that the spring had been subjected to an abnormal acid attack in pickling or phosphating which had resulted in considerable absorption of hydrogen by the metal and hence embrittlement. The part was concluded to have cracked during phosphating or excessive acid pickling before phosphating.","PeriodicalId":231268,"journal":{"name":"ASM Failure Analysis Case Histories: Failure Modes and Mechanisms","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":"126183100","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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