Professional Documents
Culture Documents
Failure Analysis: The Failure May Be Due To Following Reasons
Failure Analysis: The Failure May Be Due To Following Reasons
THE FAILURE MAY BE DUE TO FOLLOWING REASONS THE FABRICATION SEQUENCE INHERENT METTALURGICAL PROBLEMS. IMPROPER SELECTION OF CONSUMABLES. IMPROPER APPLICATION OF PROCEDURE
LINIENCY IN DESIGN
LACK OF CLEAR CONCEPT
FAILURE OF TEST COUPENS OF DISHED END PETAL TYPE HOT PRESSED/ COLD SPINNING
THE WPS/PQR ESTABLISHED USING E7018 ELETRODES FOR SA515Gr70 MATERIAL GAVE SATIASFACTORY RESULTS FOR PETAL D.E
THE SAME WPS FOUND TO VARIATION IN RESULT WHEN USED FOR COLD SPUN /HOT PRESSED D.E. WITH WELD JOINT.
ANALYSIS
THE HOT PRESSED ./COLD SPUN D.E.UNDERGOES NORMALISING OPERATION WHICH IS NOT ACCOUNTED IN WPS
WHEN USING E7018 ELECTRODES ,UTS DROPS BY 50-70 N/mm sq WITH NORMALISING OPERATION
SOLUTION
IT IS RECOMMENDED TO USE E7018A1 WELDING CONSUMABLES.
Sl.No
CONSUMALE TYPE
AS WELDED
SR
NORMALISED
1 2
E7018 E7018A1
530 540
525 535
480 530
PROBLEM: THE SPIRAL COIL WELD JOINTS WERE FOUND TO BE LEAKING AFTER SHORT SEVICE OF SIX MONTHS ANALYSIS: THE WELD JOINTS EXAMINED USING DP INDICATED SEVERE MICRO FISSURING ON ALL THE JOINTS. THE EXAMINATION OF WPS/PQR INDICATED ROOT RUN BY GTAW & BALANCE BY SMAW OF E 8018-B6 CONSUMABLES.
FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER(CONTD) ON EXAMINATION OF CONSUMABLE RECORDS ,BEING 2.5MM IN SIZE ,NO MECHANICAL TEST RESULS WERE CALLED FOR & HENCE NOT PROVIDED. REVIEW TAKING INTO CONSIDERATION TYPE OF BASE MATERIAL WHICH IS PRONE FOR INTERMEDIATE HARDANABLE MICRO STRUCTURE & MICRO FISSURING UNDER RESTRAIANT, IT WAS RECOMMENDED TO USE E8018-B6 DULY QUALIFIED WITH TEKKAN Y-GROOVE TEST TEKKEN Y-GROOVE ASSEMBLY
20mm
CROYOGENIC APPLICATION
TYPICAL REQUIREMENT 15 mil LE AT MINUS 196 Deg.C LOW CORBON(<0.04),NITROGEN(<0.05), FERRITE(2%) BASIC SLAG
ANALYSIS
THE CONVENTIONAL E308L-16 ELECTRODES GAVE ERRATIC RESULTS. EVENTHOUGH THE E308L-15 ELECTRODES FOUND TO GIVE GOOD RESULTS, RADIOGRAPHIC RESULTS WERE NOT CONSISTANT IT WAS POSSIBLE TO OBTAIN GOOD PERFORMANCE AS WELL AS CONSISTANT RESULT BY MODIFYING THE PRODUCT E308L-16 WITH CONTROLLED FERRITE(<2%)
RESULTS OF E308L-16 BATCH TEST BATCH CVN AT -196 C LE mil UTS mpa %E FN %
A
B C
32.3
40 35.3
17
19.2 19
536
543 564
45.4
49 47
2
1.5 1
CORROSION APPLICATION
TEST DURATION
CORR.RATE mpy
REMARKS
NO OF CRACKS
FERRITE NO.
A B C
14 10.5 5.5
5 1 -
ANALYSIS
THE COMMONLY AVILABLE CONSUMABLES IN ABOVE GRADES COMMONLY HAD FERRITE 8-16% THESE CONSUMABLES EVEN THOUGH SUITABLE FOR THIN SECTIONS,GAVE VERY LOW %E WHEN USED ON THICKER JOINTS/SR APPLICATION THE REASON FOR ABOVE WAS DUE TO FORMATION OF INTERMEDIATE BAINITE(SIGMA) PHASE
SOLUTION
USE MODIFIED CONSUMABLES WITH CONTROLLED FERRITE OF 6-9% & QUALIFY THE SAME WITH SR AT 680deg C FOR 1HOUR WHEN WELDING JOINTS THICKER THAN 20mm ,BUTTER THE CS/LAS WITH E309&WELD WITH SUITABLE SSCONSUMABLES.
4 8 16
POST WELD HT TEMP POST WELD HT FOR 10 HOURS
C 600 C
D 700 C
B 500 C
A 550 C
TYPICAL MECHANICAL PROPERTIES OF WELDING CONSUABLES STEEL WELDING USED FOR DISSIMILAR
Sl. No Type
T e c h n I c a l C o n d i t I o n
UTS N/mm2
550 550 550 550
% E
30 30 30 30
UTS N/mm2
-
% E
-
UTS N/mm2
550-650 550-650 550-650 550-650
% E
30 30 30 30
Ferrite
UTS N/mm2
650- 750 550- 650 550- 6O0 580- 680
% E
10 30 30 25
Ferri te
4 6
1 2 3 4
16 8
PROBLEMS RELATED
1-2MM
SEQUENCE OF WELDING
FIRST SIDE
BASE METAL WELDING BG &SECOND SIDE BASE MEATL WELDING FIRST LAYER
BARRIER LAYER
5mm
3mm
REPAIR WELDING
CS/LAS WELDING TO BE RESTRITED 1MM BELOW ORIGINAL BARRIER LAYER LEVEL OF BARRIER LAYER 5mm DEPTH
t- (d+b)
15CDV6
Due to its excellent mechanical properties, the material 1.7734 / 15CDV6 meets the requirements of international quality- and safety standards. High yield strength and excellent weldability. Weldable without subsequent heat-treatment, in both conditions High resistance of the weld, without subsequent heattreatment (Rm > 980 N/mm2).
CHEMICAL
C
MIN MAX 0.12 0.18
Cr
1.25 1.5
Mo
0.8 1.0
V
0.2 0.3
Material Number
Tensile Strength
Yield Strength
N/mm2 (MPa)
1.7734.4 / 15CDV6 1.7734.5 / 15CDV6 700 980 1180
N/mm2 (MPa)
550 NORMALISED 790 TEMPERED
THE MATTER WAS TAKEN TO HIGHEST LEVEL & JOB WAS RE-HEAT TREATED TO SUIT THE APPLICATION WITH RE-ESTABLISHED WPS/PQR.
THE BASIC PROBLEM WAS THE FIRM(DEFENCE) WAS WORRIED ABOUT SHARING BASIC D ESIGN PARAMETERS WHICH COULD HAVE RESULTED IN CATASTROPHIC FAILURES.TIMELY ACTION HAS AVERTED THE SAME.