Peculiarities of stress corrosion fracture of sensitized and neutron irradiated chromium-nickel austenitic steel

The results of SEM studies of fracture surfaces for the 12Cr18Ni9 austenitic steel ruptured under a fixedtensile load in FeCl3 water solutionand in air are presented. The samples of austenized, sensitized at 650° and irradiated with neutrons (to 1020n/cm2) steel were examined. It was shown thatirradiation hardening and sensitizing annealing increased the susceptibility of steel to intergranular cracking in corrosive solution. Structural features of formation of the strain-induced α’-martensite and its reinforcing effect on fracture in various environments are discussed.

Investigation of Zohr Hydraulic Flying Lead Reaction Drive Shafts

The HFLs for the Zohr Phase 1 project contains a cobra head at each end that incorporates the female couplers and the locking mechanism. Beginning in February 2020, and with the most recent incident recorded in September 2020, a total of 4 supplied HFL reaction drive shafts (RDS) failed subsea, resulting in partial separation of the HFL cobra heads from their respective fixed stabplates with a loss of hydraulic supply pressure and subsequent automatic well shut ins. HFL failures occurred on both the XT and HIPPS side of the HFLs on 3 different well sites. A further RDS tested at the laboratory from the UTA end of an HFL showed signs of microscopic cracking consistent with the failed specimens suggesting it may have had the potential to lead to a failure in the future. The failed HFLs were retrieved and returned onshore, the HFL locking mechanism was stripped down to gain access to the failed ends of the RDS and a visual inspection was performed. The initial inspection after partial disassembly to reveal the inside of the HFL locking mechanism identified that the RDS had completely failed at a location on the threaded portion of the RDS. Surface deposits were collected from each probe surfaces and analysed using scanning electron microscopy (SEM), together with energy- dispersive X-ray (EDX). A piece 10mm long was taken from each of the four probes for quantitative chemical analysis. Standard tensile and Charpy V-notch impact and Vickers hardness surveys have been conducted. Each of the failed probe exhibited an intergranular fracture surface morphology. This was confirmed through metallography/EBSD. No single initiation site was located on fracture surfaces, although some regions showed a mixed fractographic morphology, with some small areas of micro-void coalescence. Secondary intergranular cracking and corrosion was apparent at various locations, in each of the failed probes, including in thread roots, in samples 183 and 188, and just above the thread, in sample 052. These observations points towards an environmentally assisted cracking mechanism (i.e. stress corrosion cracking). Metallography revealed two layers within surface films, both in cracks and on the fracture surface: an inner layer, rich in nickel, sulphur and aluminium, and an outer, rich in copper and sulphur. Mechanical testing and chemical analysis revealed consistent results across the probes. The probe material was specified as Nibron Special (CuNi14Al3/DIN 2.1504) with a size of 2inch. Would be challenging to get the full root cause of using this material for subsea applications as it is resistant to seawater. Another factor contributed allows risk of material failure which should be eliminated for all subsea industry or taken into consideration to avoid further failures.

Physical Properties and Failure Analysis for Bolts in the Diaphragm Valve by Micro Morphology and Metallographic Test

The reasons leading to the fracture of 17-4PH stainless steel bolts in the isolation valve of a power plant was analysed by means of morphology analysis, chemical analysis, hardness test, metallographic test, pitting corrosion test and intergranular corrosion test, SEM and other detection means. The results show that there are many corrosion pits on the surface of the valve stem in the seawater system, the corrosion pits is extend and propagation in intergranular cracking. The main reasons to valve stem fracture are the low corrosion resistance of the material and the improper aging process of heat treatment.

Microstructural Evolution of 9CrMoW Weld Metal in a Multiple-Pass Weld

9CrMoW steel tubes were welded in multiple passes by gas-tungsten arc welding. The reheated microstructures in the Gr. 92 weld metal (WM) of a multiple-pass weld were simulated with an infrared heating system. Simulated specimens after tempering at 760 °C/2 h were subjected to constant load creep tests either at 630 °C/120 MPa or 660 °C/80 MPa. The simulated specimens were designated as the over-tempered (OT, below AC1, i.e., WT-820T) and partially transformed (PT, below AC3, i.e., WT-890T) samples. The transmission electron microscope (TEM) micrographs demonstrated that the tempered WM (WT) displayed coarse martensite packets with carbides along the lath and grain boundaries. Cellular subgrains and coarse carbides were observed in the WT-820T sample. A degraded lath morphology and numerous carbides in various dimensions were found in the WT-890T sample. The grain boundary map showed that the WT-820T sample had the same coarse-grained structure as the WT sample, but the WT-890T sample consisted of refined grains. The WT-890T samples with a fine-grained structure were more prone to creep fracture than the WT and WT-820T samples were. Intergranular cracking was more likely to occur at the corners of the crept samples, which suffered from high strain and stress concentration. As compared to the Gr. 91 steel or Gr. 91 WM, the Gr. 92 WM was more stable in maintaining its original microstructures under the same creep condition. Undegraded microstructures of the Gr. 92 WM strained at elevated temperatures were responsible for its higher resistance to creep failure during the practical service.

The Corrosive Improvement with High Temperature Laser Surface Treatment of AA7075

a recently developed AA7075 was subjected to solid solution, high temperature laser surface treatment and artificial aging. The microstructure evolution and precipitation behavior were examined, and their effects on corrosion behavior and corrosion cracking were analyzed. The results show that the coarse η phase disappears and a large number of smaller η phases are formed after high temperature laser surface treatment. Most of the phases dissolved into Al matrix during solution, a fine η phase precipitated in laser treatment. η′ appeared in the high temperature laser surface treatment samples. It was concluded that reasonable laser scanning power owned the best corrosion resistance, lower intergranular corrosion tendency. Both lower laser scan power and higher scan power samples were susceptible to the intergranular corrosion, and the intergranular cracking was observed. In contrary, the reasonable sample which the laser power is 1000W showed much better corrosion resistance due to the coarsening and separation of grain boundary precipitations.