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Subject: search.filters.subject.Metallurgical failure analysis

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    Premature failure of superheater tubes in a fertilizer plant
    (Elsevier Ltd, 2021) Dsilva, P.C.; Bhat, S.; Banappanavar, J.; Kodancha, K.G.; Hegde, S.R.
    This work presents an unique premature failure of steam superheater tubes in a fertilizer plant. The heat exchanger tube bundle made of SA 213 grade T11 steel suffered from wall thinning in the vicinity of baffles causing reduction in wall thickness of the tubes leading to perforation and leakage of steam from the tube-side into the shell-side during service. The work presents details of metallurgical failure analysis involving: site inspection, visual inspection, chemical analysis, X-Ray diffraction, microstructural analysis, and computational fluid dynamics analysis. The qualitative and quantitative chemical analyses and X-Ray diffraction carried out on superheater residue followed by microstructural analysis of failed tubes confirmed that the tubes suffered from aggressive corrosion attack at certain locations due to hot flue gas carrying alkaline salts and refractory fines. To understand the mechanism of thinning and the reasons for the tube bundle failure only at certain locations, a detailed CFD analysis was carried out on model of the heat exchanger which simulated the flow pattern of the hot gas. The analysis comprehensively demonstrates that the hot gas carrying both corrosive and erosive species caused erosion-corrosion of the tubes in the vicinity of tube-baffle junction that lead to wall thinning and subsequent failure of the tube bundle. Suitable remedial measures are suggested to minimize such failures in future. © 2020 Elsevier Ltd
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    Failure Analysis of a Bucket Elevator Shaft
    (Springer, 2021) Gurudath, B.; Kumawat, K.K.; Tejaswi, V.; Sondar, P.R.; Rakshan Kumar, J.K.; Hegde, S.R.
    Present work investigates the in-service break down of a bucket elevator in a chemical processing plant. The elevator was used for lifting bulk Di-Ammonium Phosphate and broke down due to premature failure of a shaft made of EN19 steel. The investigation comprises a detailed metallurgical failure analysis involving site visit, visual inspection, fractography, and metallography. The investigation reveals that, about 2 years prior to the failure, the shaft was tack-welded to the sprocket hub and a gib-head key near the keyway to avoid the frequent loosening of the key. The inspection during the site visit confirms that the shaft-sprocket assembly was subjected to in-service jerky loading condition along with uneven stress distribution due to misaligned counterweight. The investigation concludes that a crack was initiated in the shaft at the heat affected zone of the tack-welded spot, propagated transversely by fatigue due to in-service cyclic loading, and terminated catastrophically by a brittle fracture during the service. Tack welding, coupled with uneven stress distribution in the shaft due to misaligned counterweight system, is adjudged the root cause of this failure. Suitable remedial measures are suggested to avoid such a failure in the future. © 2021, ASM International.
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    Failure of hydraulic lathe chuck assembly
    (Elsevier Ltd, 2022) Sondar, P.R.; Gurudath, B.; Ahirwar, V.; Hegde, S.R.
    Present work provides a detailed failure investigation of a hydraulic lathe chuck assembly that comprises a plunger, three jaws, and three jaw-carriers that are made of carburized, tempered and sub-zero treated EN36C steel. The chuck assembly suffered premature failure of the plunger and one of the jaw carriers during the service in a CNC lathe. The investigation comprises a detailed metallurgical failure analysis involving: visual inspection, fractography, metallography, and hardness measurements. The analysis concludes that plunger failed first by fatigue fracture that is originated at a sharp corner of a T-slot. The mating jaw-carrier failed in the next event due to instant misalignment and overstressing during the lathe operation. The investigation concludes that design flaw and improper heat treatment cycle as the reasons for the premature failure of the assembly. Through experimental simulation of the heat-treatment cycles using EN36C specimens, the work suggests that carburizing, cryogenic treatment and then tempering is the proper sequence for achieving the best combination of mechanical properties that should extend the service life of the chuck-assembly. © 2021 Elsevier Ltd
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    Creep cavitation damage of K-type thermocouples
    (Elsevier Ltd, 2023) Rakshan Kumar, J.K.; Bhattacharjee, D.; Dsilva, P.; Praveen, R.; Hegde, S.R.
    This work investigates premature failure of K-Type thermocouples that were used in a chemical processing plant. The work presents a detailed metallurgical failure analysis involving, site visit, visual inspection, metallography, optical microscopy, scanning electron microscopy, and fractography. The analysis reveals that the thermocouple wires endured creep cavitation damage during service and eventually failed by creep-rupture. Interestingly, the influence of creep on the degradation of industrial thermocouples is not detected and reported thus far. By presenting analytical stress calculations using temperature dependent materials properties, the current work reveals that the thermal expansion mismatch between various materials of thermocouple causes high tensile stresses in the thermocouple wires during elevated temperature services. The work concludes that high tensile stresses at elevated temperature operation caused premature creep failure of the K-type thermocouples. © 2022