Engineering Failure Analysis 52 (2015) 97–108

Contents lists available at ScienceDirect

Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Failure analysis and weld ability improvement

of 35%Cr–45%Ni heat resistant alloy
A. Reihani a, R. Derakhshandeh Haghighi b,⇑
a
Department of Materials Science and Engineering, Bandar Abbas Branch, Islamic Azad University, Bandar Abbas, Iran
b
Department of Materials Science and Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran

a r t i c l e i n f o a b s t r a c t

Article history: The failure of Ethan cracking tubes in radiant chambers after four years service has been
Received 13 December 2014 analyzed. The microstructure evolution during solution annealing and its affect on the
Received in revised form 7 March 2015 mechanical properties and repair welding of 35Cr–45Ni heat resistant alloy was studied
Accepted 15 March 2015
by means of optical and electron microscopy and by mechanical testing in samples welded
Available online 25 March 2015
both by GTAW and SMAW process. HAZ cracking after welding of cracked or creeped tubes
due to formation of continuous brittle carbide network was overcome by localized solution
Keywords:
heat treatment. Analysis revealed that dissolution of continuous brittle secondary
Welding
35Cr–45Ni heat resistant alloy
carbide precipitates promoted an increase in ductility of about 20% which is enough to
Solution annealing accommodate the thermal stresses during thermal fluctuations at service.
Carbide network Ó 2015 Elsevier Ltd. All rights reserved.
Tube

1. Introduction

Due to high metallurgical stability, good oxidation and corrosion resistance and satisfactory creep strength, nickel-base
superalloys are extensively used to manufacture component part for the petrochemical industry. Most of these materials are
cast from melts rich in nickel and chromium. Elements such as niobium, titanium, vanadium and zirconium are commonly
added to impart higher creep resistance as they form stable precipitates at the operating temperatures. These alloys are used
as tubes, flanges, headers and coils in furnaces, transfer lines, heaters as well as petrochemical, chemical and commercial
heat treating industries [1–4]. The high content in chromium and nickel of these alloys promotes an as cast microstructure
composed of a network of primary carbides within an austenitic matrix. Exposure at high service temperatures promotes the
occurrence of different metallurgical phenomena that affect the mechanical properties of these alloys [1–3]. The major
drawback of these alloys is their very low ductility at room temperature, their elongation to rupture being as low as 2%.
This specific characteristic results in a particular behavior of the material regarding fracture. It means they are prone to
cracking in service [5]. Due to prolonged exposure to high temperature, the microstructure of material is subjected to
degradation. Although sufficient care is taken in the selection of materials, design and operations, failure can hardly be
avoided because of various reasons such as overheating [6], stress corrosion cracking [7], creep and fatigue [8–10]. The
assembly by welding or the necessary weld-repair following in-service failure of these alloys is very difficult and generally
induces cracking, the material being unable to properly accommodate the welding thermal stresses through a proportioned
plastic strain [5]. Welding induces thermal gradient and stresses, which creates distortion or cracks if the material is too
brittle. It is assumed that welding a material with no risk of cracking requires a minimum ductility of 4% or more which

⇑ Corresponding author. Tel.: +98 7118328074; fax: +98 7284692111.

E-mail address: derakhshande@shirazu.ac.ir (R.D. Haghighi).

http://dx.doi.org/10.1016/j.engfailanal.2015.03.005
1350-6307/Ó 2015 Elsevier Ltd. All rights reserved.
98 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108

is assessed by an elongation to rupture in tension test [11]. In order to enhance ductility slightly, solution annealing to dis-
solve secondary carbides is recommended [12]. The physical metallurgy of the as cast heat resistant alloys is complex
because of different elements in the alloy. So, that the welding of these alloys is complex too mainly because of segregation
of these alloys during solidification and formation of eutectic compounds and secondary phases [13]. On the other hand,
heating for a long time at temperatures above 900 °C and heat treatment after welding promotes the formation of
strain-age-cracking (SAC) which is a reheat cracking because of making the microstructure more brittle [13]. According to
Branza et al. [14] in order to prevent cracking of cast heat resistant steels during repair welding one should consider the
selection of welding filler metal, the number of welding passes and pre heat treatment. Ireri et al. [15] compared the
microstructure of an as cast 35Cr–45Ni heat resistant alloy with the age hardened one at 750 °C for about 1000 h. They
proved that the as cast alloy consists of an austenitic matrix with primary carbides of NbC and M7C3 while the age hardened
alloy consists of secondary carbides of M23C6 and Nb3Ni2Si which are suitable places for crack initiation during repair
welding.

1.1. Background

Pyrolysis furnaces are used in the chemical and petrochemical industries. The furnaces are composed of several vertical
tubes. There are gas torches in the furnace chamber which act as the heat source. In pyrolysis furnaces, heavy hydrocarbons
are broken to light hydrocarbons at temperatures beyond 850 °C. The life span of the 35Cr–45Ni heat resistant alloy tubes in
Pyrolysis furnaces which are used in this study according to the manufacturing company is about 10 years working at 850 °C.
However after about 4 years the tubes were severely deformed. In some cases, longitudinal and circumferential cracks were
formed. It is rational to cut the deformed part of the tube and substitute with a new one by a repair welding process.
However, the repair welding of a new as cast material (35Cr–45Ni) to the old tube by GTAW or SMAW method was not suc-
cessful and the welding cracks appeared again in HAZ region. In order to solve the problem accurate microscopical investiga-
tions followed by mechanical testing should be conducted. The major aim of this study is to find a solution to avoid tube
cracking during repair welding of 35Cr–45Ni alloy and also selecting a better welding method between GTAW and SMAW.

2. Materials and methods

2.1. Sample preparation

Four specimens with the length of 200 mm  125 mm diameter  9 mm thickness were cut from 35Cr–45Ni heat
resistant alloy tubes exposed at service temperature. Among these four specimens, two were solution annealed. Welding
of the tubes was conducted in a way that one end was an as cast 35Cr–45Ni heat resistant alloy and the other end was
one of the four specimens cut from the tubes exposed at service temperature. So, altogether four samples were prepared.
Among these four samples, two were welded by GTAW process and the others were welded by SMAW process. Table 1 shows
the samples designations used in this study.

2.2. Solution annealing procedures before welding

Two of the age hardened service exposed temperature tubes were solution annealed according to Fig. 1 by heating to

1150 °C with a rate of 150 hC and keeping them at this temperature for 1 h and then rapid cooling by dry air at a rate of
C
200 min
under the transformation temperature of 600 °C and cooling the samples in the ambient temperature.

2.3. Materials, specifications

(ER-35/45 Nb) filler rods for GTAW and (E-CrNiCoMo1) electrodes for SMAW process used in this study. Table 2 shows the
chemical composition of BM1, BM2, and weld metal of sample GT-01and weld metal of sample SM-03. The base metal
chemical composition is the same for BM1 and BM2 according to this table and no changes in chemical composition were
seen. The only difference is in the composition of the weld metal in GTAW and SMAW which arises from the difference in
composition of the filler metals used in this study. The composition of the tube material is in agreement with the necessary
requirements for the tubes used in pyrolysis furnaces.

2.4. Welding parameters

GTAW was performed with an average operation current and voltage of 90 A and 25 V, respectively. The electrode wire
cm Lit
feed speed of about 6 min , a tungsten electrode of 2.5 mm diameter and argon shielding gas flow rate of 12 min was used.
SMAW was applied with an average operation current and voltage of 80 A and 23 V, respectively. An electrode of 3 mm
cm
diameter with a travel speed of 11 min was used.
 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108 99

Table 1
The sample designations used in this study.

Sample designation Description

GT-01 The sample welded by GTAW, without solution annealing
GT-An-02 The sample welded by GTAW, with solution annealing
SM-03 The sample welded by SMAW, without solution annealing
SM-An-04 The sample welded by SMAW, with solution annealing
BM1 The base metal of the as cast 35Cr–45Ni heat resistant alloy
BM2 The base metal of the age hardened 35Cr–45Ni heat resistant alloy at service temperature
HAZ1 The heat affected zone for the as cast 35Cr–45Ni heat resistant alloy
HAZ2 The heat affected zone for the age hardened 35Cr–45Ni heat resistant alloy at service temperature

Fig. 1. Solution annealing procedures before welding of the age hardened service exposed temperature tubes.

Table 2
Chemical composition of BM1, BM2, and weld metal of sample GT-01 and SM-03.

Specimen Chemical composition

%Si %Mn %Cr %Mo %Cu %Fe %Co %Ti %Al %Nb %W %V %C %S %Zr %Ni
BM1 1.3 1.1 34 0.003 0.01 16.5 0.03 0.09 0.07 0.88 <0.01 0.04 0.32 0.009 0.04 Bal.
BM2 1 1 33 0.002 0.01 17.7 0.05 0.04 <0.002 0.79 <0.01 0.03 0.36 0.01 0.03 Bal.
Weld metal for GT-01 1 0.95 34 0.17 0.005 17 0.18 0.07 0.002 0.64 0.01 0.03 0.32 0.01 0.07 Bal.
Weld metal for SM-03 0.5 0.06 21 8 0.009 1.51 10 0.24 0.8 0.06 0.03 0.04 0.05 0.005 0.03 Bal.

2.5. Microscopical investigation and X-ray diffraction analysis

The metallographic specimens obtained were rubbed with 80–2000 mesh sand paper, as a result, their surfaces were
cleaned and the cross sectional surfaces were polished by 3 lm diamond paste and solvent. For microstructural examination,
the specimens were etched with a solution of 10 g oxalic acid in 100 ml of water. A scanning electron microscope (SEM) was
used to evaluate the microstructure of selected samples. X-ray analyses of selected areas were also obtained (EDX). Chemical
composition of the samples was determined by spectrometer. The presence of different phases was identified by X-ray
Diffraction (XRD).

2.6. Microhardness measurement

The Vickers microhardness measurements were carried out on the polished cross section of the specimens using a 10 kg f
load. The average microhardness for three different locations was reported. Different areas such as base materials, heat
affected zones and the weld metals were tested.

2.7. Tensile test

Tensile test was performed at room temperature for the as cast material and the service exposed tubes after welding by a
Gotech machine. The tensile test sample was fabricated from the longitudinal direction of the tubes. The average value is
taken after two specimens per condition were tested. The fracture surface through the tensile tested specimens was
examined by scanning electron microscope in order to identify the fracture characterizations.
100 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108

Fig. 2. The microstructure of the as cast base metal (BM1) for sample GT-01.

Fig. 3. The microstructure of the age hardened service exposed temperature tubes (BM2) after 15,000 h.

3. Results and discussion

3.1. Base metal

Fig. 2 shows the microstructure of the as cast base metal (BM1) for sample GT-01. According to this figure the as cast
material is composed of primary carbide particles. Carbide particles are uniformly distributed in austenitic matrix. These
uniformly distributed carbide particles enhance the creep resistance of the alloy.
Whereas according to Fig. 3 the carbides in the base metal of the age hardened service exposed temperature (BM2) after
15,000 h, form a continuous network and also secondary carbides in the austenitic matrix (red1 arrows on the micrograph).
This continuous network is very brittle which may cause catastrophic failure when load is applied. It should be noted that dur-
ing the service condition, interstitial carbon atoms which are present in pyrolysis tubes react with carbide-forming elements
and precipitate in the grain boundaries that influence on the composition and volume fraction of secondary precipitates that
are too brittle [16,17].
Fig. 4(a and b) shows the optical micrograph from the outer and inner surface of the age hardened service exposed tubes,
respectively. The carburization depth of the outer surface and inner surface is about 280 lm and 129.8 lm, respectively.
According to Grabke et al. [18] carburization is an internal carbon enrichment and carbide formation which occurs mainly
in industrial processes where Cr–Ni–Fe alloys are applied at high temperature (T > 800 °C) in carbonaceous atmospheres and
the carburization rate is related to carbon activity of the gas. Factors such as decarburization and carbon diffusion have
important roles on coarsening of precipitates [17].
When the protective oxide scale (such as Cr2O3) which is nearly impermeable for carbon diffusion is failed the carburization
at inner surface of the tube occurs. Conversion of Cr oxides to non-protective carbide phases and also structural defects in the

1
For interpretation of color in Fig. 3, the reader is referred to the web version of this article.
 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108 101

Fig. 4. The optical micrograph from the (a) outer surface and (b) inner surface of the age hardened service exposed tubes.

Fig. 5. The formation of a thick layer of coke inside the tube.

oxide layer, at high temperatures is one of the mechanisms leading to the failure of oxide layer and internal carburization
occurrence [18]. Carbon is transferred into the metal phase and diffuses inward and reacts with the alloying elements which
form stable carbides, M23C6 and M7C3 with Cr and MC with M = Ti, Zr, V, Nb. After that, an internal carbide precipitate zone is
formed which is oversaturated with dissolved carbon. After oversaturation, the remaining matrix disintegrates and the out-
growth of coke from the weak point of the tube starts [18].
Fig. 5 shows the formation of a thick layer of coke inside the tube. A thick layer of coke inside the tubes results in a
temperature gradient between inside and outside the tubes. In fact, concentration of heat outside the tubes and overheating
leads to early precipitation of brittle secondary carbides and age hardening of the tubes. This phenomenon reduces the heat
transfer and increases the heat transfer coefficient [19,20]. Furthermore, because of lower expansion coefficient of coke than
the tube material, during heat fluctuations the tube wall resist against the produced thermal stresses and early fracture occurs.
It should be noted that, above (T > 1100 °C), nitriding can occur from the outer diameter of the radiant tubes by
penetration of nitrogen into oxide films (Cr2O3 and SiO2) and reaction with chromium and precipitation of nitrides. In this
case, carbonitrides form by uptake of chromium and nitrogen [18].
Fig. 6 presents the influence of solution annealing on microstructure of the age hardened service exposed tubes. It is
obvious that solution annealing breaks the continuous carbide networks to a great extent which was presented before in
Fig. 3.
The carbide dissolution is better presented in Fig. 7 where the boundary between the age hardened service exposed tube
and the solution annealed region is obvious.

3.2. Weld metal

The amount of interdendritic phases in SM-03 and SM-An-04 samples is less than GT-01 and GT-An-02. This is because of
less amount of alloying elements in SMAW electrode (E-CrNiCoMo1) than GTAW filler rod (ER-35/45 Nb) used in this study.
102 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108

Fig. 6. The influence of solution annealing on microstructure of the age hardened service exposed tubes.

Fig. 7. The boundary between the age hardened service exposed tube and the solution annealed region.

The dendrite arms in SM-03 and SM-An-04 samples are coarser than GT-01 and GT-An-02, mainly because of higher heat
input in SMAW process than GTAW. Fig. 8(a–d) shows the denderitic microstructure of weld metal for GT-01, GT-An-02,
SM-03 and SM-An-04 samples, respectively. In GTAW samples, because of higher amount of alloying elements the condition
for accumulation of the alloying elements on the solidification front of the weld metal is provided and the interdenderitic
phases are finer and better distributed.
On the other hand, the cooling rate in GTAW is higher than SMAW, which leads to a fine dendritic microstructure that
makes more obstacles along the crack growth path. The solidification in these alloys which contain Nb, is completely com-
plex. According to [13] there are three stages during solidification of these alloys. (1) Liquid to austenite (L ? V). (2) Liquid to
austenite and NbC (L ? V + NbC) and at the end of solidification. (3) Liquid to austenite and Laves phase (L ? V + Laves).
Fig. 9 demonstrates the microstructure (V/Laves and V/NbC) for weld metal of FC–SMAn-04 sample. The Laves phase is an
intermetallic phase with an stoichiometry of A2B where ‘‘A’’ designates the elements such as (Co, Cr, Fe, Ni) and ‘‘B’’
designates (Mo, Si, Ti, Nb). Because of the plate like morphology and high hardness of these phases, brittle fracture is
inevitable. Depletion of the matrix from solid solution strengthening elements such as Cr, Mo and W leads to a decrease
in the alloys strength.
Fig. 10 shows the optical micrograph of the carbides at the grain boundaries in weld metal of GT-An-02 sample. The
microstructure of the samples welded by GTAW is composed of carbides such as NbC. Because of higher cooling rate in
GTAW, there is no chance for the formation of brittle Laves phase.

3.3. SEM and EDX analyses

Back scatter electron analysis of the outer and inner surface of the age hardened service exposed tubes demonstrates dark
and light regions. Fig. 11(a and b) presents the SEM micrograph of the (BM2-GT-01) sample from the inner and outer surface,
respectively. The EDX analysis of these light and dark regions is presented in Table 3.
 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108 103

Fig. 8. The optical micrograph of denderitic microstructure in weld metal of (a) GT-01, (b) GT-An-02, (c) SM-03 and (d) SM-An-04 samples.

Fig. 9. The microstructure (V/Laves and V/NbC) for weld metal of SM-An-04 sample.

Fig. 10. The optical micrograph of the carbides at the grain boundaries in weld metal of GT-An-02 sample.
104 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108

Fig. 11. The SEM micrograph of the (BM2-GT-01) sample from (a) inner and (b) outer surface.

Table 3
The EDX analysis of the inner and outer surface of (BM2- GT-01) sample.

Location on SEM micrograph EDX analysis

%Fe %Si %Cr %Oxygen
Dark region/inner surface 0.74 1.9 87.75 2.45
Light region/inner surface – 61.44 – 16.24
Dark region/outer surface – 1.59 79.61 3.55
Light region/outer surface – 58.03 – 19.34

Fig. 12. The SEM micrograph (back scatter electron (BSE) and secondary electron (SE)) of the precipitates for (a) GT-01, (b) GT-An-02, (c) SM-03 and (d) SM-
An-04 samples.

The higher oxidation potential around the tubes in the furnace at the outer surface is because of the higher amount of
oxygen. The less amount of oxygen inside the tube because of the presence of H2 and CO, affects the amount of oxygen in
the precipitates. It should be noted that according to [21,22] silicon plays an important role because it stimulates the trans-
formation of NbC to brittle G-phases such as Nb3Ni2Si. It is obvious that according to EDX analysis the amount of silicon is
high both inside and outside the age hardened service exposed tube. In order to analyze the precipitates in the microstruc-
ture of different samples, the EDX analysis was carried out on four points namely, A, B, C and D. Fig. 12(a–d) shows the SEM
 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108 105

Table 4
EDX analysis for the specified points (A, B, C, D) on micrographs.

Sample Region %Fe %Ni %Nb %Ti %Cr %C %Co %Mo

HAZ2-GT-01 A 6.31 8.92 – – 79.25 5.51 – –
B 4.59 13.56 52.82 4.76 20.17 4.09 – –
C 5.3 6.3 – – 82.23 6.16 – –
D 9.65 26.04 30.48 6.24 24.25 3.04 – –
HAZ2-GT-An-02 A 8.54 17.11 – – 71.17 3.18 – –
B 7.32 21.49 36.65 – 30.01 4.53 – –
C 9.68 20.24 – – 58.01 4.67 – –
D 6.61 20.59 38.48 5.24 22.92 6.16 – –
HAZ2-SM-03 A 5.92 15.08 0.81 – 68.51 – – –
B 4.48 50.15 15.51 0.53 15.46 1.35 – –
C 8.43 41.86 6.06 – 36.49 – 0.91 –
D 6 38.03 8.22 – 32.61 1.78 1.94 –
HAZ2-SM-An-04 A 7.19 16.7 – – 70.05 5.22 – –
B 6.48 37.15 11.26 – 33.21 1.57 – 4.68
C 4.17 8.58 – 83.29 – 3.95 – –
D – 12.98 – – 77.02 10 – –

Fig. 13. The X-ray diffraction analysis of (a) as cast and (b) age hardened tube at service temperature.

micrograph (back scatter electron and secondary electron) of the precipitates for sample GT-01, GT-An-02, SM-03 and SM-
An-04, respectively. The secondary electron images does not distinguish between the different types of carbides in the
microstructure, but the images by back scatter electron reveals that the carbides have different chemical composition as
heavier elements appear in lighter tones. Table 4 also presents the EDX analysis for the points on micrographs.
The points with high amount of chromium and carbon are chromium carbide precipitates. The points with high amount of
niobium and carbon are NbC precipitates. The points with higher amount of titanium may be brittle G-phase or (Ni3(Al, Ti))
precipitates. However, the dissolution of precipitates and breaking of carbide networks due to solution annealing is obvious
in these micrographs. According to Fig. 13(a and b) which shows the X-ray diffraction analyses of the as cast and the age
hardened tube at service temperature, one can see that the as cast alloy consists of an austenitic matrix with primary
carbides of NbC and M7C3. The presence of bright NbC particles and dark primary Cr7C3 particles in Fig. 14 (points A and
B) confirms the XRD pattern. On the other hand, the age hardened alloy at service temperature consists of secondary carbides
of M23C6 and brittle Nb3Ni2Si phase which are suitable places for crack initiation during welding. The X-ray diffraction
analysis, is an indication of the transformation of primary M7C3 carbides into M23C6 and also the formation of a silicide phase
which identifies the nature of the particles much better.

3.4. Vickers microhardness

Table 5 shows the Vickers microhardness of the samples which has been taken from different points such as weld metal,
heat affected zone (HAZ) and base metal of the as cast and age hardened service exposed tubes. Because of exposure to high
temperature and age hardening of the base metal of age hardened service exposed tube (BM2), the microhardness is higher
than the as cast tube (BM1). The weld metal hardness in all of the samples is higher than the base metals or HAZ. Because of
higher cooling rate in GTAW than SMAW and the finer microstructure of dendrites in GTAW than SMAW and also due to
lower amount of alloying elements in SMAW electrode used in this study, the weld metal microhardness of sample
GT-01 and GT-An-02 is higher than SM-03 and SM-An-04.
106 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108

Fig. 14. The SEM micrograph (back scatter electron (BSE)) of the bright NbC particles and dark primary Cr7C3 particles for the as cast metal.

Table 5
Vickers microhardness of the samples used in this study.

Vickers microhardness
Sample BM1 BM2 HAZ1 HAZ2 Weld Metal
GT-01 208 219 235 234 245
GT-An-02 207 222 235 233 249
SM-03 210 219 236 231 225
SM-An-04 205 225 234 235 222

Table 6
Tensile test data at room temperature for different samples.

Sample Location of fracture Yield (MPa) Ultimate tensile strength (MPa) % Elongation
As cast material BM 245 450 10
GT-01 BM2 – 354 5
GT-An-02 BM2 – 319 6
SM-03 BM2 – 334 4
SM-An-04 BM2 – 279 6

Fig. 15. The fracture surface of (a) GT-01 and (b) GT-An-02 samples after tensile test.
 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108 107

3.5. Tensile test and fracture surface characterization

According to data obtained from tensile test at room temperature in Table 6, it is obvious that all of the samples fail from
(BM2) side with about 100 MPa lower ultimate tensile strength than the as cast material and also with lower percent
elongation. The lower ultimate tensile strength of the samples can be attributed to the formation of carbide networks in
the microstructure.
Fig. 15(a and b) shows the fracture surface of sample GT-01 and GT-An-02 after tensile test, respectively. As mentioned
before, the samples fractured at the BM2 side, respectively. The fracture surface of sample GT-01 contains micro cracks and
voids which have been highlighted by the arrows on the micrograph in Fig. 14a. Although GT-An-02 sample has been solu-
tion annealed, because of the presence of brittle carbides in the microstructure the fracture surface reveals a well- faceted
brittle appearance without any plastic deformation prior to fracture which is an indication that the austenitic matrix has lost
its capacity to deform plastically. However, the 20% enhancement in percent elongation of the annealed sample, confirms
better mechanical property of the solution annealed samples than the age hardened service exposed tubes.

4. Conclusions

It was found that by solution annealing of the age hardened service exposed 35%Cr–45%Ni heat resistant alloy tubes
and then welding these heat treated tubes to as cast material with primary carbides in austenitic matrix, the problem
of cracking during repair welding of age hardened tubes is solved. In fact solution annealing breaks the continuous and
brittle secondary carbides network to a great extent. Using GTAW process instead of SMAW has better results because
of its lower heat input and the finer microstructure which is obtained. Repair welding, either by GTAW or SMAW without
any solution annealing was not successful and HAZ cracking formed after welding. Decarburization of the inner and outer
portion of the age hardened tubes leads to depletion of the carbon atoms from the matrix and diminishing of carbides.
Analysis revealed that dissolution of continuous brittle secondary carbide precipitates promoted an increase in ductility
of about 20%. Moreover, the weld metal after GTAW has the highest microhardness. It seems that the maintenance
condition of the tubes was not desirable. The main problem is the carbon deposition on inner wall of the tubes and
creation of a thick and porous layer of coke. This phenomenon reduces the heat transfer. In fact, concentration of heat
outside the tubes and overheating leads to early precipitation of brittle secondary carbides and age hardening of the tubes.
Furthermore, because of lower expansion coefficient of coke than the tube material, during heat fluctuations the tube wall
resist against the produced thermal stresses and early fracture occurs. To avoid such overheating, precautions should be
taken. It is necessary to check the tube temperature periodically and one should ensure that the temperature is lower than
the design temperature.

Acknowledgement

The authors thank the support from the Islamic Azad University, Bandar abbas Branch for providing the funding for this
research.

References

[1] Hou WT, Honeycombe RWK. Structure of centrifugally cast austenitic stainless steel: part1 HK40 as cast and after creep between 750 and 1000 °C.
Mater Sci Technol 1985;1:385–9.
[2] Zhu SJ, Zhao J, Wang FG. Creep crack growth of HK40 steel: microstructural effects. Metall Trans A 1990;21A:2237–41.
[3] Thomas CW, Borshevsky M, Marshal AN. Assessment of thermal history of niobium modified HP50 reformer tubes by microstructural methods. Mater
Sci Technol 1992;8:855–61.
[4] Barbabela GD, Almeida LH, Silveria TL, Lemay I. Role of Nb in modifying the microstructure of heat resistant cast HP steel. Mater Charact
1991;26:193–7.
[5] Haro S, Lopez D, Velasco A, Viramontes R. Microstructural factors that determine the weldability of a high Cr-high Si HK40 alloy. Mater Chem Phys
2000;66:90–6.
[6] Kumar RA, Kuma SS, Nath TY, Swaminathan J, Das G, Chaudhuri S. Analysis of failed reformer tubes. Eng Failure Anal 2003;10:351–62.
[7] Bhaumik SK, Rangaraju R, Parameswara MA, Bhaskaran TA, venkataswamy MA, Roghuram AC. Failure of reformer tube of an ammonia plant. Eng
Failure Anal 2003;9:553–61.
[8] Konosu S, Koshimizu T, Lijima T, Maeda K. Evaluation of creep-fatigue damage interaction in HK40 alloy. J Mech Des Trans 1993;115:41–6.
[9] Gong JM, Tu ST, Yoon KB. Damage assessment and maintenance strategy of hydrogen reformer furnace tubes. Eng Failure Anal 1999;6:143–53.
[10] Woo Nam S. Assessment of damage and life prediction of austenitic stainless steel under high temperature creep-fatigue interaction condition. Mater
Sci Eng A 2002;322:64–72.
[11] Colwell RL, Hoffman JJ. Weld cracking in modified heat resistant castings, a microstructural investigation. In: Proceedings of the NACE international
annual conference corrosion; 1998. paper 423.
[12] Ebert HW. Fabrication of HK40 in the field. Weld J 1976;55:939–45.
[13] DuPont J, Lippold JC, Kiser SD. Welding metallurgy and weldability of nickel-base alloys. 1st ed. New Jersey: John Wiley; 2009.
[14] Branza T, Deschaux-Beaume F, Sierra G, Lours P. Study and prevention of cracking during weld-repair of heat resistant cast steels. J Mater Process
Technol 2009;209:536–47.
[15] Ireri A, Sustaita T, Seergio HR, Martha P, Guerrero M, Maribel DL, et al. Aging of a cast 35Cr–45Ni heat resistant alloy. Mater Chem Phys
2012;133:1018–23.
[16] Imizcoz FG, Lopez P, Alvarez LFV, Andres C. Use of titanium and zirconium in centrifugally cast heat resistant steel. Mater Sci Technol 2007;23:528–34.
[17] Borjali S, Allahkaram SA, Khosravi H. Effects of working temperature and carbon diffusion on the microstructure of high pressure heat resistant
stainless steel tubes used in pyrolysis furnaces during service condition. Mater Des 2012;34:65–73.
108 A. Reihani, R.D. Haghighi / Engineering Failure Analysis 52 (2015) 97–108

[18] Grabke H, Schütze M. Corrosion by carbon and nitrogen: metal dusting, carburisation and nitridation. Abington: Woodhead Publishing LTD; 2007.
[19] Jaganathan S, Krishna G, Manojkumar G, Prabirkumar R, Rabindranath G. Failure analysis and remaining life assessment of service primary reformer
heater tubes. Eng Failure Anal 2008;15:311–31.
[20] Laigo J, Christien F, Legall R, Tancret F, Furtado J. SEM, EDS, EPMA-WDS and EBSD characterization of carbides in HP type heat resistant alloys. Mater
Charact 2008;59:1580–6.
[21] Soares GDA, Almeida LH, Silveria TL, Lemay I. Nb additions in HP heat resistant cast stainless steels. Mater Charact 1992;29:387–96.
[22] Shinozaki K, Kuroki H, Nakao Y, Nishimoto K, Inui M, Takahashi M. Deterioration of weldability of long-term aged HP heat resistant cast steel
containing Nb, Mo and W. Weld Int 1999;13:39–48.