Engineering Failure Analysis 138 (2022) 106415

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Engineering Failure Analysis

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

Failure analysis of a wear ring impeller

Eko Pujiyulianto *, Abdul Muhyi, Fajar Paundra, Fajar Perdana,
Hadi Teguh Yudistira, Muhammad Syaukani
Mechanical Engineering, Institut Teknologi Sumatera (ITERA), South Lampung, Lampung 35365, Indonesia

A R T I C L E I N F O A B S T R A C T

Keywords: The paper aims to analyze the cause of failure of a wear ring impeller and to analyze the quality of
Wear ring impeller the wear ring material. The analysis was conducted by common failure analysis procedure
316 L steel including chemical composition test, visual examination, microstructure examination, micro­
Stellite
hardness, and macrohardness. The results show that the sliding wear, softened material, and
Failure analysis
adhesion wear are found on the outer surface of the wear ring, and the deflection occurs on the
fracture surface. The fractography analysis indicates that the initial crack occurs due to the valley
that acts as a stress concentrator geometry, and the failure is caused by the fatigue stress. The
chemical composition test shows that the overlay material is not in accordance with technical
data. The suggestion for the corrective action is to ensure the eccentricity of the overall rotary
part, and it must use the proper material to prevent sudden failure.

1. Introduction

A pump is a device that flows a fluid and adds energy to increase the kinetic energy using rotating equipment or an impeller [1].
Nowadays, pump failure is common [2–4]. Some of the failures may be caused by the short lifetime of components [5], material
selection errors [6], design errors [7], process errors [8], and inconsistency in maintenance. The failures that often occur in pumps are
leakage, process issues, bearing failure, wear impeller, tear, and coupling failure [9–11].
In the wear impeller, there is a wear ring that is inserted into the wear casing of the impeller. The installation of the wear ring
impeller to the wear casing should not be too tight or too relaxed. If the installation is too tight, it will generate excessive heat due to
friction between the outer surface of the wear ring impeller and the inner surface of the wear casing, and it also happens because there
is no gap for fluid to flow from the discharge. The fluid acts as a coolant and lubricant. If the installation is too relaxed, the internal
pressure loss will happen, and it will reduce the pump efficiency [11]. The minimum clearance between the wear ring impeller and
wear casing is explained in API 610 [12]. After operating for a certain period, the wear ring impeller will usually experience damage
such as wear and tear. It will form a gap that will cause an internal loss, or it will cause a fracture.
Generally, the wear ring impeller is made from 316 L stainless steel with an overlay on the surface to improve the mechanical
properties of the surface [13]. The material used for the overlay has high wear resistance, high hardness, and corrosion resistance
[14–17], so it will resist the high friction, and corrosive environment. The common material used for the overlay is a stellite alloy
[13,17–19].
Fig. 1 shows the wear ring impeller that failed after being used for two weeks. The technical data as the preliminary data for the
analysis were the base material, overlay material, operating condition, and temperature which were 316 L, Stellite #12, 2980 rpm, and

* Corresponding author.
E-mail address: eko.pujiyulianto@ms.itera.ac.id (E. Pujiyulianto).

https://doi.org/10.1016/j.engfailanal.2022.106415
Received 24 February 2022; Received in revised form 27 April 2022; Accepted 8 May 2022
Available online 13 May 2022
1350-6307/© 2022 Elsevier Ltd. All rights reserved.
E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 1. The failed wear ring impeller.

Fig. 2. Specimens location.

75 ◦ C, respectively. The overlay process was conducted using plasma transferred arc welding (PTAW). Before assembling the wear ring
to the impeller, the wear ring was heated up to ±130 ◦ C, and held up to 3–5 min. After heating, the wear ring was inserted into the
impeller and followed by a tack weld in three positions for anti-rotating.
The short lifetime and the damage as shown in Fig. 1 indicate that it is necessary to identify the cause of failure of the wear ring
impeller from the fracture surface, and to analyze the quality of the material whether there is a defect in raw material i.e. macro­
segregation and microsegregation, thus the suggestion can be considered as the corrective action to prevent the failure in the future.

2. Experiment and method

The failed wear ring impeller was examined using a spectrometer (Poly Spek Neo Spectrometer, England) and EDS (Hitachi
SU3500, Japan) for the chemical analysis. The chemical analysis results were compared to standard material as per the material
certificate. The microstructure analysis was conducted using an optical microscope (Olympus, Japan). The picral and hydrochloric acid
was used as a reagent to reveal the microstructures. The microstructure analysis was conducted to ensure the quality of the material
from the microstructure whether there is a defect or not. The hardness test both micro and macro hardness was also conducted. The
microhardness test was conducted using a micro Vickers testing machine (Mitutoyo HM-200, Japan), and the macrohardness was
conducted using a Rockwell universal hardness testing machine (Zwickroell, ZHU250CL). The fractography was characterized using a
micro-camera, microscope optic (Olympus, Japan), and SEM (Hitachi SU3500, Japan).
The failed wear ring impeller was cut to provide a specimen for each test. The specimen’s location is described in Fig. 2. The
fractography analysis was conducted on specimens from locations 1 and 2, the chemical composition test was conducted on specimens

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Table 1
Chemical composition analysis of base material 316 L.
Element (wt. %) Base Material 316 L (failed wear ring) 316 L (as per certificate)

C 0.0356 ≤ 0.03
Mn 1.7631 ≤2
P 0.0178 ≤ 0.045
S 0.0109 ≤ 0.030
Si 0.6654 ≤1
Cr 18.684 16–18
Ni 10.2767 10–15
Mo 1.8456 1–3
N – ≤ 0.1
Cu 0.3688 –
Co 0.1386 –

Table 2
Chemical composition test of overlay material.
Element (wt. %) Overlay (Failed wear ring) Stellite #12 [13] Stellite #6 [13]

Cr 34,35 30 30
Co 53,57 50,95 50,95
C 6,63 1,55 1,2
W 4,28 8 4–5
Fe 1,18 <3 <3

Fig. 3. Location for analysis divided by the quadrants.

from location 3, and the microstructure test was conducted on specimens from location 4. Generally, all analyses are performed close to
the fracture region.

3. Results and discussions

Table 1 shows the chemical composition of the base material 316 L of wear ring impeller. It is compared to the standard chemical
composition of 316 L as per the material certificate. 316 L is austenitic stainless steel [20]. The L after the number indicates that the
carbon content must not exceed 0.03 %. The low carbon content is intended to avoid sensitization and the formation of carbide [21].
The main alloying elements of 316 L are C, Ni, Cr, and Mo [21].
Table 1 shows that the C and Cr elements exceed slightly the limit range of standard chemical composition. The slight excess of C
and Cr content will have the potential for chromium carbide (CrxCy) formation [21]. It happens due to the Cr has a high affinity to C,
and it will act as a strong carbide former in alloys. The high Cr content might also produce a delta ferrite [22]. Both CrxCy and delta
ferrite will reduce the ductility, toughness, and corrosion resistance of stainless steel [22]. Besides C and Cr content, Table 1 shows the

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 4. Defect on the outer surface of the wear ring impeller a) x-axis, b) quadrant 1, c) between quadrant 1 and 2, d) quadrant 3.

presence of Cu and Co elements in the base material 316 L. Compared to the standard chemical composition of 316 L as per the material
certificate, Cu and Co elements are not the main alloys of 316 L. The content of Cu and Co in the base material is up to 0.3688 and
0.1386 %, respectively. Both slight excess of C and Cr elements and the occurrence of Cu and Co elements in the base material 316 L
indicate that the material has microsegregation defects due to inappropriate chemical composition. It will affect the material prop­
erties, and its performance [6,23].
Table 2 shows the chemical composition of the overlay material. Based on the technical information, the overlay material is stellite
#12. Stellite #12 is a type of cobalt alloy that is generally used for surface hardening [13]. Some of the main alloys of stellite alloys are
Cr, C, W, and/or Mo [13]. Table 2 shows that the overlay material on the failed wear ring impeller is not a stellite #12. It can be
observed from the W content which only reaches up to 4.28%. According to the chemical composition standard of stellite alloy, the
minimum content of W in satellite #12 is 8% [13]. About 50% of the W content on stellite #12 is not fulfilled. Besides the W content,
the higher C content is found on the overlay material of the failed wear ring impeller. The higher C content will not compensate for the
lack of W content. The C and W have a different effects on stellite alloys [24]. The W content in stellite alloys acts as the major element
to increase the strength of stellite, increase the hardness by maintaining enough ductility, increase red-hardness, and increase the high
heat resistance whereas the C content only acts to increase the hardness of the stellite alloys [24]. The chemical composition analysis of
the overlay material states that the overlay material is not stellite #12, but it is closer to stellite #6. The comparisons of the chemical
composition of the overlay material on failed wear ring, chemical composition standard of stellite # 12, and chemical composition
standard of stellite # 6 are shown in Table 2. It is concluded that the overlay material is not in accordance with the technical data

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 4. (continued).

specifications. Stellite #6 and stellite #12 have different properties. Stellite #6 has lower abrasion and lower impact resistance than
stellite #12 [13]. Improper material selection will potentially cause the failure to occur faster than the component lifetime design [6].
Fig. 3 shows the area divided by quadrants on the coordinate axis. The quadrants on the coordinate axes are used to define the
defects location and fracture location on the wear ring impeller. In Fig. 3, the red arrow indicates a drilling location, the yellow arrow is
the tack weld location, and the red block is the fracture location.
Fig. 4 shows the outer surface of the wear ring impeller. Fig. 4a, 4b, 4c, and 4d show the location of the outer surface in the x-axis,
quadrant 1, fracture surface between quadrant 1 and quadrant 2, and quadrant 3, respectively. Generally, Fig. 4a-d show that the outer
surface of the wear ring impeller experience sliding wear and adhesion wear. The sliding wear occurs due to the friction between the
outer surfaces of the wear ring impeller and the inner surface of the wear casing, and the adhesion wear occurs because the melted
material sticks on the outer surface of the wear ring impeller. The melted material might be generated during the high friction that
occurs between the outer surface of the wear ring and the inner surface of the wear casing. The high friction will increase the
temperature.
Fig. 4c shows the deflection phenomenon on the fracture surface where the fracture surface is not aligned with each other. It occurs
due to plastic deformation at the stage of crack propagation and final crack. Fig. 4b shows the softened material on the outer surface of
the wear ring impeller. It is formed because the temperature of the material increases with high friction. The increasing of temperature
will soften the material. The friction between the outer surface of wear ring and the inner surface of the wear casing may occur due to

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 5. Tack weld location on the wear ring impeller: a) quadrant 4, b) quadrant 3, and c) quadrant 2.

Fig. 6. The macrohardness of the overlay and base material 316 L.

the uneccentricity of the wear ring impeller in the rotary part. The suggestion for corrective action is to ensure the eccentricity of the
overall rotary part, especially for wear ring impeller.
Fig. 5a-c show the position of the tack weld (black arrow) on the inner surface of the wear ring impeller. Fig. 5a shows the cracks
that occur in the weld metal (red arrow). It forms because the load exceeds the working load limit in the tack weld area. The excessive
load occurs because the pressure between the outer surface of the wear ring and the inner surface of the wear casing is generated during
the high friction. Besides the excessive load, the weld also has the stress concentrator geometry that could be the initial crack location
in weld metal (red arrow). In Fig. 5, the yellow arrow shows the rusting and discoloration in the HAZ area. Rusting is a kind of
corrosion defect in stainless steel caused by the improper welding process [21–22]. It happens because the passive layer is broken, and
it will reduce the corrosion resistance material [21–22].
Fig. 6 shows the macrohardness value of the base material 316 L and overlay material compared to the hardness standard value as
per technical data in the certificate. The average hardness value of the base material 316 L and the overlay is 22.56 HRC and 43.5 HRC,
respectively. The hardness standard value of the base material 316 L and the overlay #12 material is 22–32 HRC [24] and 46–51 HRC
[13], respectively. The hardness of base material 316 L falls within the hardness standard range as per the certificate, but the hardness
of the overlay is not in the hardness standard range stellite #12. It happens because the overlay material is not stellite #12, but it is
closer to stellite #6. The average hardness standard value of stellite #6 is 42 HRC [24]. The hardness of the overlay material is closer to
the hardness standard of stellite #6. It shows that the overlay material is harder than the base material 316 L.
Fig. 7a and b show the microstructure of the overlay material and base material 316 L, respectively. The diffusion layer between
overlay material and base material 316 L can be observed in Fig. 8b. The microstructure of the overlay material is a solid solution of Cr-
Co and a eutectic structure with a dendritic shape, and the microstructure of the base material 316 L is austenite with annealing

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 7. The microstructure of the material a) overlay, and b) base material 316 L.

twinning. Fig. 7b shows that the 316 L material has poor quality. It can be observed from the inclusion and small carbide that are found
within the base material 316 L. The formation of carbide might be caused by the C and Cr that exceed slightly as explained earlier.
Fig. 8a and b show the EDS results on the overlay material and base material 316 L, respectively. Fig. 8a and b state that the overlay
material is stellite #6 with cobalt as the main alloy, and the base material is 316 L stainless steel with the main alloy is Fe-Cr-Ni. The
overlay material is not in accordance with the technical information as per the material certificate.
Fig. 9a and b show the microhardness value of the overlay material, and the position of the indentation, respectively. The
microhardness of the overlay, diffusion layer, and base material 316 L is 709.579 HVN, 390,379 HVN, and 340.694 HVN, respectively.
The difference in hardness values is caused by the phase within the material. The solid solution in the overlay material causes the
overlay harder than the diffusion layer and base material 316 L. Besides the phase, the hardness of the overlay material is caused by the
size and the shape of the microstructure. The microstructure of the overlay material has a smaller grain size than the base material 316
L. The smaller grain size will increase the hardness and strength of the material [23]. It is in accordance with the Hall-Patch law as
detailed in equation (1). The corresponding relationship between mechanical strength and hardness is shown in equation (2). The σ is
yield strength, σo is material constant, d is grain diameter, k is material constant related to strengthening coefficient, HV is hardness,

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 8. EDS result a) overlay material, and b) base material 316 L.

and HVo is material constant.

(1)
1
σ = σ 0 + kd− 2

(2)
1
HV = HV 0 + kd− 2

Fig. 10a and b show the fracture location of the wear ring impeller. Fig. 10b is analyzed to define the initial cracks, crack prop­
agation, and the final crack region as shown in Fig. 11. The initial crack starts from the upper corner of the left side, and it propagates
toward the right side and toward the base material 316 L. The final crack occurs at the bottom of the right end side. Fig. 11 shows that
the base material and the overlay material have different fracture characteristics (fractography).
Macroscopically, Fig. 11 shows that the initial crack region has a pseudo-cleavage characteristic with the well-defined river. It is
indicated by the fine ridges that parallel the crack propagation direction. It states that the kind of stress that causes the fracture is
fatigue stress [25]. The fatigue stress occurs because the wear ring impeller was operated in a rotating condition. The beach mark as the
most outstanding characteristic in the fatigue fracture does not occur in the initial crack region. The detailed of the initial crack region
is shown in Fig. 12. The absence of the beach mark in the initial crack region might be caused by the rapid crack growth rate then the
rapid failure takes place [26].
The origin of the initial crack location is indicated by the yellow arrow in Fig. 11. It can be analyzed that the crack occurs due to the
sharp valley as the stress concentrator geometry on the outer surface of the wear ring impeller. The sharp valley is formed because of
the sliding wear phenomenon as explained earlier, thus the stress would be concentrated on it. The depth of the valley is 2 mm, then the

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 9. a) The microhardness of the overlay material, diffusion layer, and base material 316 L, b) the location of the microhardness test.

thickness of the wear ring impeller would be 7 mm whereas the initial thickness is 9 mm.
The crack propagates towards the right side and towards the base material 316 L as shown by the blue arrow in Fig. 12. The detailed
of the crack propagation on the base material 316 L is shown in Fig. 13. It shows that the river mark formed during the crack
propagation in the base material 316 L. The river mark is parallel to the crack propagation. The crack propagation region as shown in
Fig. 10 has the bright region (white arrow). It seems like the limit of the initiation region, namely the beach mark. The single beach
mark in the crack propagation just below the end of the bright fracture surface indicates the cyclic loading. It is in accordance with the
explanation in Ref. [27]. The single beach mark occurs due to the rapid crack growth rate [27,28].
The final crack occurs at the bottom of the right end of the base material 316 L. It can be observed from the formation of shear lip
and a rougher surface as detailed in Fig. 14. The shear lip deformation occurs because the material with a smaller size is not able to
withstand the load generated during crack propagation, and the fracture occurs when the material dimension is lower than the critical
size.
Microscopically, The fracture surface is shown in Figs. 15 and 16. Fig. 15 shows a fractography of the overlay material using SEM.
Fig. 15a is the initial crack location, and Fig. 15b is the crack propagation location. It shows that the valley is formed on the surface of
the wear ring impeller. The valley is formed due to sliding wear. It becomes the stress concentrator geometry, and it would be the initial
crack location. The initial crack has a pseudo-cleavage characteristic with well-defined river. It is indicated by the fine ridges that
parallel to the crack propagation direction. The striation does not occur in the overlay material because the overlay material is a kind of
high strength material. The striation might not occur in the high strength material above 30 HRC as explained in Ref. [25].
Fig. 16 shows a fractography of base material 316 L using SEM. Fig. 16a is the location of crack propagation in the base material 316
L, and Fig. 16b is the final crack location in the base material 316 L. The final crack location has the shear lip deformation and the
rougher surface as detailed in Fig. 13. The striation is found in crack propagation in the base material 316 L as shown in Fig. 16a. The
striation characteristic is wavy and smooth, and it indicates that the failure is caused by fatigue [25]. The dimple and micro void are
found in the final crack location as shown in Fig. 16b. The formation of dimples and microvoids is due to the tearing and decohesion

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 10. The fracture region of the wear ring impeller a) outer surface, and b) fracture surface.

Fig. 11. The fractography analysis from macrostructure.

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 12. The magnification of fractography analysis on initial crack location in the overlay material.

Fig. 13. The magnification of fractography analysis on crack propagation location in the base material 316 L.

phenomenon that occurs in the last stage of crack propagation. The finding, causes, and suggestions are detailed in Table 3.

5. Conclusion

The analysis of a failed wear ring impeller has been conducted. Based on the result of the analysis, it is concluded that the sliding
wear, softened material, and adhesion wear are found on the outer surface of the wear ring impeller. The deflection occurs on the
fracture surface of wear ring where the fracture surface is not aligned with each other. The fractography analysis indicates that the
initial crack occurs due to the valley that acts as a stress concentrator geometry on the overlay material, and the failure is caused by the
fatigue stress. It can be observed from the fractography analysis. The chemical composition test shows that the overlay material is not
in accordance with technical data as per the material certificate. The suggestion for the corrective action is to ensure the eccentricity of
the overall rotary part, especially for the outer diameter of the wear ring. It is considered to prevent the sliding and adhesion wear
defects, and it must use the proper material to prevent sudden failure.

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Fig. 14. The magnification of fractography analysis on the final crack location.

Fig. 15. The magnification of fractography analysis on the overlay material using SEM.

Fig. 16. The magnification of fractography analysis on the base material 316 L using SEM.

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E. Pujiyulianto et al. Engineering Failure Analysis 138 (2022) 106415

Table 3
Finding, Causes, and Suggestions.
Finding Causes Suggestions

The friction on the outer surface causes:
• sliding wear,
• softened material,
• adhesion wear,
The above phenomenon will cause an
increase the surface roughness that
will form the deep valley
• Deflection and fracture
The excessive friction on the surface of the wear ring impeller.
The temperature increases with excessive friction.Softened • Ensure the eccentricity of the overall
material and adhesion wear occurs due to the increase of rotary part, especially for the outer
temperature during friction, so the particle is trapped and sticked diameter of the wear ring.
on the surface.
• Ensure the quality of the material used
for wear ring impeller.
• The stress concentrator geometry occurs because of the
valley. The valley can be observed from surface
roughness and the wear pattern.
• The stress concentrator geometry becomes an initial
crack location, and the fatigue stress causes the failure.
• The deflection phenomenon occurs on the fracture
surface where the fracture surface is not aligned each
other

Author’s contributions

All authors have participated in (a) conception and design, or analysis and interpretation of the data; (b) drafting the article or
revising it critically for important intellectual content; and (c) approval of the final version.

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to
influence the work reported in this paper.

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