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Brittle Failure of Reformer Tube During Pressure Test 压力试验中重整管脆性失效
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001475
During periodic inspection of the tubes of a reformer furnace, a soapy water leak test with the tubes pressurized with nitrogen was being carried out by site personnel in a manner contrary to the policy of the organization when one of the tubes suddenly disintegrated with explosive violence. The tube approximately 30 ft. long by 6 in. diam, was constructed of three spun cast sections butt welded together. The material specified for tubes for this service was basically a 25% chromium, 20% nickel, cast stainless steel containing 0.4% carbon to optimize creep resistance. Failure initiated in the region of the tube where the dark fracture surface and columnar grain structure were evident. These features indicated the presence of a defective zone or progressive cracking which had occurred during service. Microscopic examination of sections through the zone revealed extensive creep cracking. The cracking was intergranular and followed the interdendritic columnar structure adjacent to the outer surface.
在对重整炉的管道进行定期检查时,现场工作人员违反本组织的规定,用氮气加压的管道进行肥皂水泄漏试验,这时其中一根管道突然爆裂。管子长约30英尺,宽6英寸。直径,是由三个旋转铸造节对接焊接在一起。为这项服务指定的管道材料基本上是25%铬,20%镍,含0.4%碳的铸造不锈钢,以优化抗蠕变性能。破坏开始于管的区域,在那里黑色的断口和柱状晶粒结构是明显的。这些特征表明在使用过程中出现了缺陷区或渐进裂纹。通过该区域的切片显微镜检查显示广泛的蠕变开裂。裂纹为沿晶开裂,沿枝晶间柱状组织靠近外表面。
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引用次数: 0
Failure Analysis of Launch Pad Tubing From the Kennedy Space Center 肯尼迪航天中心发射台管道失效分析
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001696
S. McDanels
Piping and structural components used in space launch facilities such as NASA's Kennedy Space Center and the Air Force's Cape Canaveral Air Station face extreme operating conditions. Launch effluent and residue from solid rocket boosters react with moisture to form hydrochloric acid that settles on exposed surfaces as they are being subjected to severe mechanical loads imparted during lift-off. Failure analyses were performed on 304 stainless steel tubing that ruptured under such conditions, while carrying various gases, including nitrogen, oxygen, and breathing air. Hydrostatic testing indicated a burst strength of 13,500 psi for the intact sections of tubing. Scanning electron microscopy and metallographic examination revealed that the tubing failed due to corrosion pitting exacerbated by stress-corrosion cracking (SCC). The pitting originated on the outer surface of the tube and ranged from superficial to severe, with some pits extending through 75% of the tube's wall thickness. The SCC emanated from the pits and further reduced the service strength of the component until it could no longer sustain the operating pressure and final catastrophic fracture occurred. Corrosion-resistant coatings added after the investigation have proven effective in preventing subsequent such failures.
美国宇航局肯尼迪航天中心和空军卡纳维拉尔角航空站等航天发射设施中使用的管道和结构部件面临极端的操作条件。固体火箭助推器的发射废水和残留物与湿气发生反应,形成盐酸,在发射过程中受到严重的机械载荷时,盐酸会沉淀在暴露的表面上。在这种条件下,304不锈钢管在携带各种气体(包括氮气,氧气和呼吸空气)时破裂,进行了故障分析。流体静力测试表明,完整油管段的爆裂强度为13500 psi。扫描电镜和金相分析表明,油管失效的原因是腐蚀点,应力腐蚀开裂(SCC)加剧。点蚀发生在管道的外表面,从表面到严重不等,一些点蚀延伸到管壁厚度的75%。SCC从坑中产生,进一步降低了组件的使用强度,直到它不再能够承受工作压力,最终发生灾难性断裂。调查后添加的耐腐蚀涂层已被证明可以有效防止后续的此类故障。
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引用次数: 0
Fractured Three-Cylinder Crankshaft 断裂的三缸曲轴
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001192
F. Naumann, F. Spies
The fracture cause had to be determined in a three-cylinder crankshaft made of chrome steel 34Cr4 (Material No. 1.7033) according to DIN 17200. The fracture occurred after only 150 h of operation. The fracture was of the bend fatigue type which originated in the fillet of the main bearing and ran across the jaw almost to the opposite fillet of the adjoining connecting rod bearing. The fillet was well rounded and smoothly machined. Thus, no reason for the fracture of the crankshaft could be found externally. No material defects were discernible in the origin or anywhere else. No cause for the crank fracture could be established from material testing. Probably the load was too high for the strength of the crank. Tensile strength could have been increased for the same material by tempering at lower temperature. Additionally, the resistance against high bend fatigue stresses or torsion fatigue stresses could have been increased substantially by including the fillet in the case hardening process.
断裂原因必须根据DIN 17200确定由铬钢34Cr4(材料号1.7033)制成的三缸曲轴。术后仅150小时发生骨折。断裂为弯曲疲劳型,主要发生在主轴承的圆角处,并沿下颚向相邻连杆轴承的相反圆角处延伸。鱼片很圆润,加工得很顺利。因此,从外部找不到曲轴断裂的原因。在原产地或其他任何地方都没有发现任何实质性缺陷。从材料试验中无法确定曲柄断裂的原因。也许负荷对曲柄的强度来说太高了。在较低温度下回火可以提高相同材料的抗拉强度。此外,通过在壳体硬化过程中加入圆角,可以大大提高抗高弯曲疲劳应力或扭转疲劳应力的能力。
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引用次数: 0
Spalling Failure of a Spur Gear 直齿齿轮的剥落故障
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001502
Lester E. Alban
A portion of two large spur tooth bull gears made from 4147H Cr-Mo alloy steel that had spalling teeth was submitted for evaluation. The gears were taken from a final drive wheel reduction unit of a very large open-pit mining truck. The parts had met the material and initial heat treat hardening specifications. The mode of failure was tooth profile spalling. By definition, spalling originates at a case/core interface or at the juncture of a hardened/nonhardened area. The cause of this failure was either insufficient or no induction-hardened case along the active profile. The cause was activated by a nonfunctioning induction hardening coil that did not or was not allowed to harden the midprofile of several teeth.
以4147H Cr-Mo合金钢制造的两个有剥落齿的大直齿公牛齿轮的一部分进行了评定。齿轮取自一个非常大的露天采矿卡车的最终驱动轮减速单元。零件满足材料和初始热处理硬化要求。失效模式为齿形剥落。根据定义,剥落发生在套管/岩心界面或硬化/非硬化区域的结合处。这种失败的原因要么是在活动剖面上没有感应硬化层,要么是感应硬化层不够。原因是由一个不起作用的感应硬化线圈激活,该线圈没有或不允许硬化几颗牙齿的中部轮廓。
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引用次数: 0
A Microstructural Examination of Hot Corrosion of a Co-Cr-Fe Alloy Cast Burner Nozzle from a Coal Gasification Plant 某煤气化厂Co-Cr-Fe合金铸造燃烧器喷嘴热腐蚀的显微组织研究
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001681
S. Cao, C. R. Brooks, G. Whittaker
A microstructural analysis has been made of a burner nozzle removed from service in a coal gasification plant. The nozzle was a casting of a Co-29wt%Cr-19wt%Fe alloy. Extensive hot corrosion had occurred on the surface. There was penetration along grain boundaries, and corrosion products in these regions were particularly rich in S, and also contained Al, Si, O, and Cl. The grain boundaries contained Cr-rich particles which were probably Cr23-C6 type carbides. In the matrix, corrosion occurred between the Widmanstatten plates. Particles were found between these plates, most of which were rich in Cr and O, and probably were Cr2-O3 oxides. Other matrix particles were found which were rich in Al, O, and S. The corrosion was related to these grain boundary and matrix particles, which either produced a Cr-depleted zone around them or were themselves attacked.
对某煤气化厂停用的燃烧器喷嘴进行了显微结构分析。喷嘴由Co-29wt%Cr-19wt%Fe合金铸造而成。表面发生了广泛的热腐蚀。沿晶界渗透,腐蚀产物中S含量特别丰富,同时还含有Al、Si、O和Cl。晶界含有富cr颗粒,可能为Cr23-C6型碳化物。在基体中,腐蚀发生在魏氏板之间。在这些薄片之间发现了颗粒,其中大部分富含Cr和O,可能是Cr2-O3氧化物。另外还发现了富含Al、O和s的基体颗粒。腐蚀与这些晶界和基体颗粒有关,它们要么在其周围形成贫铬区,要么自身受到攻击。
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引用次数: 0
Abrasive Wear Failure of a Hypoid Pinion 准双曲面小齿轮的磨料磨损失效
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001503
Lester E. Alban
A hypoid pinion made from 4820 Ni-Mo alloy steel was the driving member of a power unit operating a rapid transit car. The pinion had been removed from service at the end of the initial test period because it showed undue wear. The mode of failure was severe abrasive wear. The cause of failure was insufficient surface hardness, resulting from improper heat treatment. A service recall for the remaining pinions was immediately initiated.
由4820镍钼合金钢制成的准双曲面小齿轮是快速公交车辆动力装置的驱动部件。由于小齿轮出现过度磨损,在初始测试期结束时已停止使用。失效模式为严重的磨粒磨损。失效的原因是由于热处理不当导致表面硬度不足。立即启动了对其余部件的服务召回。
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引用次数: 0
Failure of a Polycarbonate Switch Housing 聚碳酸酯开关外壳故障
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0090463
A housing used in conjunction with an electrical switch failed shortly after being placed into service. A relatively high failure rate had been encountered, corresponding to a recent production lot of the housings, and the failed part was representative of the problem. The housing had been injection molded from a commercially available, medium-viscosity grade of PC, formulated with an ultraviolet stabilizer. In addition to the PC housing, the design of the switch included an external protective zinc component installed with a snap-fit and two retained copper press-fit contact inserts. Investigation supported the conclusion that the switch housings failed via brittle fracture, likely through a creep mechanism. The failure was caused by severe embrittlement of the housing resin associated with massive molecular degradation produced during the molding process. A potential contributing factor was the design of the part, which produced significant interference stresses between the contact and a mating retaining tab.
与电气开关一起使用的外壳在投入使用后不久就发生了故障。遇到了相对较高的故障率,对应于最近的外壳生产批次,而失败的部分是问题的代表。外壳由市售的中等粘度PC注塑成型,并加入紫外线稳定剂。除了PC外壳外,开关的设计还包括一个外部保护锌组件,该组件安装有一个卡扣和两个保留的铜压合接触插入件。调查支持的结论是,开关外壳通过脆性断裂失败,可能是通过蠕变机制。失效是由于在成型过程中产生的大量分子降解导致外壳树脂严重脆化造成的。一个潜在的影响因素是零件的设计,它在触点和配合的固定片之间产生了显著的干涉应力。
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引用次数: 0
Failure of a Bronze Pump Impeller by Cavitation Damage 青铜泵叶轮因空化损坏而失效
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0046414
Two water pumps were taken out of service because of reduced output. Visual inspection revealed considerable material loss in both impellers, which were 25.4 cm (10 in.) in diam x 1.3 cm (0.5 in.) wide and made from a cast bronze alloy. Several similar water pumps operating under nearly identical conditions, drawing water from an open tank through a standpipe, had no observable failures. Etched micrographs 100x of samples taken from the impellers showed clean, pockmarked, severely eroded surfaces, characteristic of cavitation damage. Investigation also revealed that considerable quantities of air were being drawn into the system when water in the supply tank dropped below a certain level. It was concluded that cavitation erosion (due to the uptake of air) caused metal removal and microstructural damage in the impellers. Recommendations included adding a water-level control to the piping system and excluding air from the pump inlet.
两台水泵因产量减少而停止使用。目视检查显示,这两个直径25.4厘米(10英寸)x 1.3厘米(0.5英寸)宽的叶轮都有相当大的材料损失,由铸造青铜合金制成。几台类似的水泵在几乎相同的条件下运行,通过立管从一个敞开的水箱中抽水,没有出现明显的故障。从叶轮上采集的100倍样品的蚀刻显微照片显示,表面干净,有凹坑,严重侵蚀,具有空化损伤的特征。调查还显示,当供水罐中的水降至一定水平以下时,大量空气被吸入系统。结果表明,空化侵蚀(由于空气的吸收)导致了叶轮内金属的去除和微结构的破坏。建议包括在管道系统中增加一个水位控制装置,并排除泵入口的空气。
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引用次数: 0
Rupture of Chromium-Molybdenum Steel Superheater Tubes Because of Overheating 铬钼钢过热器管因过热而破裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c0048294
The tubes of a stationary industrial boiler, 64 mm in diam and made of 1.25Cr-0.5Mo steel (ASME SA-213, grade T-11) failed by two different types of rupture. Noticeable swelling of the tubes in the area of rupture was revealed by visual examination. The tubes with slight longitudinal splits were interpreted to have failed by stress rupture resulting from prolonged overheating at 540 to 650 deg C as the microstructure exhibited extensive spheroidization and coalescence of carbides. The larger ruptures were tensile failures that resulted from rapid overheating to 815 to 870 deg C as a completely martensitic structure was revealed at the edges of the ruptures in these tubes because of rapid quenching by escaping fluid. The prolonged-overheating failures were concluded to have been the primary ruptures and that local loss of circulation had caused rapid overheating in adjacent tubes. Poor boiler circulation and high furnace temperatures were believed to have caused the prolonged overheating.
一个固定式工业锅炉的管子,直径64毫米,由1.25Cr-0.5Mo钢(ASME SA-213,等级T-11)制成,因两种不同类型的破裂而失效。目视检查发现破裂处管腔明显肿胀。由于微观结构表现出广泛的球化和碳化物的聚结,具有轻微纵向裂缝的管被解释为由于540 ~ 650℃长时间过热导致的应力破裂而失效。较大的断裂是由快速过热至815 ~ 870℃引起的拉伸失效,由于泄漏流体的快速淬火,在这些管的断裂边缘显示出完全的马氏体组织。长时间的过热故障被认为是主要的破裂,局部的循环丧失导致了相邻管道的快速过热。锅炉循环不良和炉温过高被认为是造成长时间过热的原因。
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引用次数: 0
Creep Rupture of a Carbon Steel Furnace Tube 碳素钢炉管蠕变断裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.modes.c9001726
Paul W. Ogden
A carbon steel furnace tube which should have given good service for ten years ruptured after one year. The tube showed obvious swelling at the point of rupture, and the bulged surface of the tube was oxidized at a temperature far above the design temperature. There was little or no loss in wall thickness due to corrosion or scaling, and the tube wall was thinned to a knife edge at the rupture. Metallographic examination showed the condition of the material was satisfactory. The failure was mechanical in nature, typical of short time creep rupture. The localized oxidation indicated improper furnace operation or blockage of the tube. The furnace was checked and found to have a burner tip out of order. After the tip was repaired, localized overheating was minimized and further premature failures did not occur.
一根本应使用十年的碳素钢炉管在使用一年后破裂。管在破裂点出现明显的膨胀,管的膨胀面在远高于设计温度的温度下发生氧化。由于腐蚀或结垢,管壁厚度几乎没有损失,并且管壁在破裂时薄到刀刃。金相检验表明材料的状况令人满意。破坏性质为机械破坏,为典型的短时间蠕变破坏。局部氧化表明炉操作不当或管道堵塞。炉子经过检查,发现有一个燃烧器尖端坏了。在尖端修复后,局部过热被最小化,进一步的过早故障没有发生。
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引用次数: 0
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ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
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