METALLURGICAL DAMAGE

MECHANISM AND
ASSESSMENT

BY

P.SUNDARAMOORTHY
BHEL – TRICHY
Crept components after completing their
designed life are examined for their “Fitness for
the Purpose” or “Life Extension Programme” as
per the code requirements.

Revised IBR–November 1998 made in-situ

metallography – Replication as a mandatory
requirement during periodic inspection in life
extension programme (Temperature > 400°C).

Materials are selected for the indented purpose

based on their properties during initial design
stage.
COMMONLY USED SEAMLESS STEEL TUBE SPECIFICATIONS IN BOILER PRESSURE
PARTS AND APPLICABLE SERVICE TEMPERATURES
Nominal Product ASME CSN DIN BS Temperature
composition limit
CS Tube SA 192 -- St 35.8 BS 3059 427°C
SA 210 A1 -- St 45.8 P2 S2 45
SA 210 C --
CS Pipe SA 106 B -- St 35.8 BS 3602 427°C
SA 106 C -- St 45.8 HFS 27
1/2 Mo Tube SA 209 T1 -- 15 Mo 3 -- 482°C
1 Cr ½ Mo Tube SA213 T12 -- 13 Cr Mo 44 Bs 3059 535°C
P2 S2 620
1 Cr ½ Mo Pipe SA 335 P12 15111.1* 13 Cr Mo 44 BS 3604 535°C
HF 620
11/4 Cr ½ Mo Tube SA 213 T11 -- -- -- 552°C
21/4 Cr 1 Mo Tube SA 213 T22 -- 10 Cr Mo 910 BS 3059 577°C
P2 S2 622/50
21/4 Cr 1 Mo Pipe SA 213 T22 -- -- BS 3604 577°C
HF 622/31
½ Cr ½ Mo1/4 V Tube -- 15123.1 14 Mo V63 +BS 3604 577°C
CD 660
½ Cr ½ Mo1/4 V Pipe -- 15123.1 14 Mo V63 +BS 3604 577°C
HF 660
18 Cr 8 Ni Tube SA 213 TP304H -- -- -- 704°C
18 Cr 10 Ni Tube SA 213 TP321H -- X 10 Cr NiTi 189 -- 704°C
4C Ti 0.6
18 Cr 10 Ni Tube SA 213 TP347H -- -- -- 704°C
8C Co+Ta
18 Cr 10 Ni Tube -- -- -- BS 3605 822 704°C
5C Ti 0.7 T1
*Contains: vanadium of ¼ % ; +Discontinuing specification.
 COMMONLY USED SEAMLESS STEEL TUBE SPECIFICATIONS IN BOILER
PRESSURE PARTS AND APPLICABLE SERVICE TEMPERATURES
Nominal Product ASME CSN DIN BS Temperature
composition limit
21/4Cr1/4Mo Tube SA 213 T23 -- 7CrWVMoNb9-6 -- 600°C
1/4V11/5W B Nb (EN)
N Al Ti
9Cr1Mo1/4VCb Tube SA 213 T91 -- X10CrMoVNb9-1 -- 610°C
N (Ti Zr) Pipe SA335 P91 -- (EN)

9Cr1/2Mo1/4VCb Tube SA 213 T92 -- X10CrMoWVNb -- 610°C

13/4W B N(Ti Zr) Pipe SA335 P92 -- 9-2 (EN)

1Mn1/2Mo11/4Ni Pipe SA335 P36 -- -- --

3/4CuNbVNAl

18Cr8Ni3CuNb Tube SA213 Super -- -- -- 704°C

304H (S30432)

Ni Base Alloys -- -- -- -- -- >720°C

Sub Critical: 165 to 240 bar – 540 to 565°C

Supercritical: 280 bar – 600 to 620°C
Advanced Supercritical: 370 bar – 700 to 720°C
 Effect of alloying element in steel
Sl Alloying Properties Melting
No. element point (°c)
01. Carbon C ↑Tensile Strength And Hardness. 3500
↓ Ductility
02. Silicon Si ↑ Tensile Strength And Density 1414
03. Manganese ↑ Tensile Strength, Wear And Corrosion Resistance 1221
Mn
04. Phosphorus P Detrimental to steels. To be kept less than 0.03 to 0.05% 44
05. Sulphur S It renders steel brittle and so harmful Permissible limit is 444
0.025 to 0.03 % max. Reduces Weldability.
06. Chromium Cr ↑ Tensile Strength, Resistance To Corrosion And Wear & 1920
Resistance To Heat And Scaling.
07. Nickel, Ni Ensures good through hardening. Improves toughness. 1453
Used along with chromium in SS to have resistance to heat,
scaling and corrosion
08. Molybdenum ↑ Tensile Strength, Heat Resistance. 2622
Mo ↑ Hardenability And Toughness
09. Vanadium V ↑ Tensile Strength, Heat Resistance 1920
10. Tungsten W ↑ Tensile Strength, Heat Resistance 3380
11. Cobalt Co ↑ Hardness, Heat Resistance 1492
12. Aluminum Al ↑ Resistance To Heat And Scaling 658
13. Copper Cu ↑ Strength And Yield Point, ↓ Elasticity. 1084
Renders Resistance To Rusting.
14. Nitrogen N Gives Resistance To Rusting, Acid And Heat. -210
15. Titanium Ti Used As Alloying Element in Austenitic, Corrosion 1727
Resistance Steel As Stabilizer.
16. Tantalum Ta Used As Stabilizer in Austenitic SS 3030
17. Niobium Nb Used As Stabilizer In Austenitic SS 2420
 POST WELD HEAT TREATMENT TEMPERATURES FOR PRESSURE VESSELS
(Temperature in Deg C)

MATERIALS IBR ASME Sec I 2001(PNo) ASME B31.1 2001 BS 1113/ 1999 BHEL's Practice

Carbon steels 600±20 593 min(P1) 600-650 550-600 610°±15

½ Mo Steels 620-660 593 min(P3) 600-650 -- 610°±15

1Cr ½ Mo Steels 620-660 593 min(P4) 700-750 620-680 665°±15

2¼ Cr 1 Mo Steels 650-750 677 min(P5A) 700-750 680-730 695°±15

5 Cr ½ Mo Steels -- 677 min(P5B-1) -- 735-780 --

9Cr 1 Mo Steels (T9/P9) -- -- -- 740-780 --

9Cr 1 Mo ¼V 0.1 Nb 0.05 745°±15

-- 704 min(P5B-2) 700-760 735-780
N Steels(T91/P91) 760°±10

½ Cr ½ Mo¼V -- -- -- 680-720

12 Cr1Mo¼V½Ni
-- -- -- 720-760 750°±10
(X20CrMoV121- DIN 17175)
Replication: Test Method ASTM E1351

This is an in-situ metallography technique.

Thick walled components subjected to creep

service are examined for their microstructures
using this technique.

Structural zones deviating vastly from normal,

e.g. decarburisation, were ground off from the
surface prior to replica documentation.

The component to be examined is fine ground

using emery grits ranging from coarse to fine.
Fine Grinding Using Emery Grits (Flapper Wheel) Under Progress at Site
The microscopical appearance of slight creep
damage may be strongly influenced by the
surface preparation. i.e. mechanical or
electrolytical polishing, and etching.

Select the appropriate polishing technique for

getting a mirror like surface on the component
surface.

Mechanical Polishing: Diamond Paste of

different size particles (10µm to 0.5µm) with
coolant.
Mechanical Polishing Under Progress at Site
Electrolytic Polishing: Alcohol + Acid Mixture

Steel: 10 ml Perchloric Acid + 90 ml Butoxy

Ethanol

Etching: Select appropriate etchant to reveal

the microstructure.

CS and LAS: 3% Nital

HAS: 1: 3 (Con HNO3: Con HCl ) +Methonal

Replication: Cellulose acetate film / paper of

thickness 25µm and acetone.
 Cellulose Acetate Film After Blackening

Polished and Etched Surface

Blackening to improve the reflection of the
film and transfer the film to glass slide using
double gum tape.

Gold sputtering at lab to further improve the

reflectivity of the film and for viewing at
higher magnifications in OM as well as SEM.

Microstructure examination, capturing and

image analysis.

Assigning spheroidisation level and creep

rating to the microstructure .
The Film is Examined Before Transferring to Glass Slide
The Film is Transferred to Glass Slide for Examination at Lab
 MASTER CURVES FOR ESTIMATION OF METAL
TEMPERATURE AND REMAINING LIFE FRACTION.
Prolonged exposure of Carbon and low alloy steels
to elevated temperature in their normal heat treated
condition undergo changes in their microstructure,
particularly in the carbide phase.

This is the commonly

known as “spheroidisation”
of the carbide phase.

This phenomenon can be used to get a rough

estimate of the mean metal temperature,
experienced by the steel in service.
 THE CLASSIFICATION OF LEVEL OF
SPHEROIDISATION IN 2 ¼ CR 1MO STEEL -
SCHEMATIC SKETCH
 THE CLASSIFICATION OF LEVEL OF
SPHEROIDISATION IN 2 ¼ CR 1MO STEEL
- SCHEMATIC SKETCH Contd….
Hence Spheroidised microstructures are
classified as below into 6 levels: (Ref: R.Viswanathan, Journal of
Pressure Vessel Technology, vol.107, August 1985, Transaction of ASME.PP 218-225)

IL. As received condition / original microstructure

of the material
II L. In-situ spheroidisation of the carbide phase
III L. Complete spheroidisation of the carbide
phase and partial dispersion within the matrix
IV L. Same as level III and the degree of dispersion
of the carbide phase is more than level III
V L. Degree of carbide dispersion is more than
observed in level IV
VI L. Complete spheroidisation of the carbide
phase and complete dispersion within the matrix
GRAPHICAL REPRESENTATION BASED ON
MICROSTRUCTURE FOR ½MO, 1¼CR½MO AND
2¼CR 1MO, MATERIALS: (Ref: R.Viswanathan, Journal of
Pressure Vessel Technology, vol.107, August 1985, Transaction of
ASME.PP 218-225)

X-axis: For a particular level of Spheroidisation and

service hours

Y-Axis: The estimated mean metal temperature

Data were analysed using Larson - Miller parameter

for taking into account the combined effects of
times and temperature.
P=T(C+ log10t) Where T- Temp in °K,
C =20 (Constant) and t – Time in Hours
 HAZ

WM

SA106 Gr.C Pipe material - Fresh RHH outlet weld joint 1.5 lakhs Hrs

Primary DSH Pipe Bend 1.5 lakhs Hrs

 HAZ

WM

Long Seam Weld Joint Cir Seam Weld Metal

Drum Weld Joints After 100,000 Hrs of Service

However estimates from these optical
Microstructural Spheroidisation levels are
only approximate, since they are influenced
by the original (prior to service)
microstructure, and also the actual chemical
composition of the material.

Master curves follows

REAMAINING LIFE FRACTION ESTIMATION:

Evaluation of replicas from headers and pipes,

reveal the extent of spheroidisation and creep
cavitation, which is the normal mechanism of
creep damage for the commonly used low alloy
steels.

Five levels of creep cavitation are recognized

-as visually seen, under optical microscope
 In accordance with a long lasting practical
experience the creep damage classes were
defined as follows: (Ref.: VGB – TW 507)
Creep Creep Damage Conditions
Rating
0 As received, without thermal service load

1 Creep exposed, without cavities

2 (A) Advanced creep exposure - isolated cavities

3 (B) Advanced Creep damage - oriented cavities

4 (C) Advanced creep damage - micro cracks

5 (D) Large creep damage - macro cracks

 (5)

(4)

(3)

(2)

Ref: High Temp Component life Assessment By G.A. Webster & R.A. Ainsworth
 REMAINING LIFE ASSESSMENT (RLA)
REPLICATION AND METALLURGICAL EVALUATION

CREEP DAMAGE CLASSIFICATION SYSTEM PROPOSED BY WEDAL AND NEUBAUER

Five levels of creep cavitation are related to an
“A-parameter” which is commonly used as one of
the quantitative creep damage parameter.

“A-parameter” is the fraction of cavitated

boundaries, and the same has been related to
remaining life fraction through certain
mathematical creep models.
The commonly used qualitative damage rating (as
reported in replica analysis reports) are shown in
the same graph on the Y-axis for getting an
approximate estimate of remaining life fraction.

The approximate range of A-parameter

corresponding to various damage ratings (as used
on the graph) are as given below. These values
are typical for 2¼Cr1Mo steel.

The graph in the next slide shows the remaining

life fraction as a function of A-parameter.
Reference: Sri.R.Viswanathan, Journal of Pressure Vessel Technology, vol.107, August 1985
(EPRI)
Tests to estimate the Remnant Life of Serviced
Tubes:
1. Visual Examination
2. Dimensional measurements
3. Chemical composition & Deposit Analysis
4. Macro Examination: Steam-side oxide scale
measurement (in-situ at site)
5. Hardness measurement
6. Flattening Test to detect damage due to
Hydrogen embrittlement
7. Micro Examination: Microstructure – Other
Damages
8. Tensile Test if required
9. Creep Test for RH and SH Tubes.
Visual examination for any macro level damage,
deposits, presence of oxide scales, pittings etc.

Dimensional measurement reveals overheating

if any, erosion, corrosion etc during service.

Chemical composition of the tubes were

determined using Vacuum OES in which C, S & P
are also estimated.

Water side Deposit Analysis: 40mg/cm² max

allowed. Chemical cleaning may be suggested
based on inside deposit analysis.
Macro examination for any defects and steam
side oxide scale thickness measurement to
estimate the extent of overheating temperature
using Larson- Miller Parameter.

Logx = 0.00022(T+460) / (20+logt)-7.25

x- scale thickness in mils
T- Temp in °Rankine (T°R=T°F+460)
t – Service in Hrs.
Hardness Measurement:
Vickers Hardness with 10 kg load as per ASTM
E92 on the wall thickness of the tube after due
specimen preparation.
Hardness values reflects the Tensile strength of
the material and related to microstructure.

Lower values than the min requirements

indicate overheating / structural degradation.

Flattening Test as per ASTM A450 / A370:

Height H = (1+e)tD / (e+t)

e – Constant 0.07 for MCS

t-Wall thickness
D-Outside Diameter
Tube section of 63.5 mm length is flattened to
the height H. The ID corroded region where
deposits are observed shall be under max
tension during test.

Cracked specimen
indicating damage due to
Hydrogen embrittlement.

No cracks will be seen if other than Hydrogen

damage.
MICRO EXAMINATION:

A ring section of the tube is micro examined

after polishing to mirror like surface and
etching with suitable etchant depending on
the chemical composition of the material.

Micro examination is conducted through out

the section of the specimen for any defects
and microstructure using OM and SEM.

The level I L microstructures of various tube

materials is shown in the next two slides.
SA210 A1 850X SA213T11 – 340X

SA213T12 – 500X SA209 T1 – 340X

SA213 T22 – 340X SA213 Type 347 H

SA213T91 – 340X
Spheroidised Microstructures and creep cracks

Spheroidisation Level – I L Spheroidisation Level – II L

Spheroidisation Level – IV L Spheroidisation Level – VI L

Microstructures of T91 T91 – Mild overheating

Creep cracks in T22 Material

 Graphitization in CS

Weld

HAZ

C - Migration

Carbon Migration in DMW

Copper segregation - ID
 OVERHEATING STRUCTURES OF WW TUBES

SHORT TERM OVERHEATING

(<AC1)

ORIGINAL MICROSTRUCTURE
 OVERHEATING STRUCTURES OF WW TUBES

SHORT TERM OVERHEATING

(AC1 TO AC3)

ORIGINAL MICROSTRUCTURE
OVERHEATING STRUCTURES OF WW TUBES

SHORT TERM OVERHEATING TO >AC3)

ORIGINAL MICROSTRUCTURE
 H2 DAMAGE IN WW TUBES

ID

ID

H2 Damage-As polished H2 Damage- Etched

Tube Microstructure
 CORROSION FATIGUE IN WW TUBES

Oxide filled parallel cracks on ID – Cu segregation –

No microstructure damage
CIRCUMFERENTIAL CRACK
ON OD DUE TO THERMAL
FATIGUE AND DEPOSIT &
METAL LOSS ON ID – WW
TUBE
 OD

ID
THERMAL FATIGUE CRACKS ON OD

Cu

ID-circumferential cracks OD- circumferential cracks

DISSOLVED OXYGEN
(O2) PITTING IN
SA209 T1 – SH COIL
PITS ON ID MICROSTRUCTURE

Max depth of the pit is about 2.26mm

against the wall thickness of 3.66mm
measured at the pit location
SA213 TP347H MATERIAL - SCC
 TUBE HAZ

Weld

TUBE HAZ

SA213 TP347H material - SCC