Article
Materials Science, Multidisciplinary
Chenyang Du, Chang Liu, Xiaowei Li, Baolin Liu, Jianyu Lu, Xinli Tan, Ce Song
Summary: Ethylene pyrolysis furnace, a crucial equipment in the ethylene production industry, relies on the pyrolysis furnace tube as its core component. The tube, made of Cr35Ni45Nb centrifugal casting alloy material, operates under high temperature and hydrocarbon medium for prolonged periods. Common failure issues include carburization, high-temperature creep cracking, thermal shock and fatigue, overheating, creep expansion, and bending. Carburization is identified as the primary cause of furnace tube failure. This study focuses on the carburization layer thickness of HP series (ASTM HP grade) furnace tube material and tests the coercivity of tubes with varying carburization layer thickness using a magnetic analyzer. The relationship between carburization layer thickness and coercivity is analyzed to develop an engineering method for testing carburization layer thickness. The fitting of experimental data achieved a 97% accuracy rate, confirming the validity and accuracy of the method.
FRONTIERS IN MATERIALS
(2023)
Article
Materials Science, Multidisciplinary
Ju-Chan Jin, Soochul Cho, Kihyuk Kim, Hoseop Sim, Byung Gyu Park, Young-Kook Lee
Summary: This study compared the microstructures and intergranular corrosion resistances of two stainless steel clad plates (STS 316L/A516-70N and STS 304L/A516-70N) fabricated without Ni interlayers using the same hot rolling and normalizing conditions. It was found that the thickness of the grain-boundary carburized layer was thinner in STS 316L due to Mo atoms segregated at the grain boundaries. Both stainless steels had carbides on their free surfaces, and STS 304L also had some amount of d ferrite. However, the corrosion resistance of the free surfaces of both stainless steels was not compromised.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
LingMin Yao, RuiKun Wang
Summary: The study found that the thermal stability of nano-structured materials significantly affected the intergranular corrosion of Super304H steel, with nano-twinned structures showing superior performance compared to nano-grained structures. The results indicated that maintaining the strain value below saturation was critical for achieving high thermal stability, good IGC resistance, and suppression of recrystallisation-induced precipitation.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Materials Science, Multidisciplinary
Husaini Ardy, Thomas Albatros, Afriyanti Sumboja
Summary: The present paper presents a case study on the failure investigation of duplex stainless steel (UNS S31803) in a shell and tube heat exchanger with seawater as cooling medium. Despite its high strength and resistance to corrosion, the heat exchanger experienced material degradation and numerous tube failures. The examination revealed the presence of a white biofilm containing CaCO3 and corrosion of the austenite grains, indicating crevice corrosion caused by microbiological-induced corrosion (MIC). Recommendations to prevent similar failures are also provided in this paper.
Article
Materials Science, Multidisciplinary
Ali Nazemi Harandi, Abdoulmajid Eslami, Abbas Bahrami, Asghar Bakhtafrouz, Maryam Yazdan Mehr
Summary: This study analyzes the failure of two reformer tubes used for hydrogen production. Tube A, containing titanium, failed after 46,000 hours of operation while Tube B, without titanium, showed higher thermal stability and creep resistance. The failure of Tube A was caused by the coalescence of creep pores and the creation of grain boundary cracks. SEM images showed initiation and growth of creep pores next to chromium carbide particles and the formation of microcracks in Cr23C6 carbides.
Article
Chemistry, Physical
Jing He, Qian Liu, Minglin He, Jiaxing Li, Shuai Wang
Summary: This study investigated the mechanism of hydrogen embrittlement in Ni fabricated by laser-based powder bed fusion. In the presence of hydrogen, the Ni failed in a brittle mode with a transgranular-like fracture surface. This unusual fracture morphology is caused by the special grain shape induced by the laser-based manufacturing process, and the failure process is mainly attributed to intergranular decohesion. Annealing of the printed sample improved its elongation and mitigated hydrogen embrittlement. The dislocation cellular pattern formed in additive manufacturing is considered detrimental to hydrogen embrittlement resistance.
INTERNATIONAL JOURNAL OF HYDROGEN ENERGY
(2023)
Article
Materials Science, Multidisciplinary
Hyeong Min Heo, Sunghwan Yeo, Jun Hwan Kim, Sung Ho Kim, Jong Ryoul Kim
Summary: This study investigates the grain structure, particle segregation, and texture of boron-modified 9Cr-2W steel tubes obtained through different heat treatments. The results show that the normalized heat-treated tubes exhibit improved grain structure and texture development, leading to a significant reduction in failure rate.
MATERIALS TODAY COMMUNICATIONS
(2022)
Article
Chemistry, Physical
Yong Jiang, Ning Sun, Yawei Peng, Jianming Gong
Summary: This paper investigates the stability of low-temperature-gaseous-carburization (LTGC) layer in AISI316L stainless steel, finding that the carburized layer remains phase stable below 400 degrees C, with thickness and hardness stable below 300 degrees C and a maximum service temperature of 200 degrees C to maintain beneficial surface compressive residual stress. The thickness reduction of the carburized layer due to oxidation is also an important factor impacting its stability.
SURFACES AND INTERFACES
(2021)
Article
Materials Science, Multidisciplinary
D. A. Macatangay, G. W. Kubacki, R. G. Kelly
Summary: Localized corrosion susceptibility represents a risk to the long-term performance of additively manufactured alloys. The unique microstructures resulting from additive manufacturing can have a significant impact on corrosion susceptibility and morphology. The response to standardized testing can also vary for additively manufactured alloys compared to traditional alloys. Parameters during the manufacturing process can greatly affect the susceptibility through the lifetime of the liquid phase.
Article
Chemistry, Physical
Xu Wang, David John Kukulka, Wei Li, Weiyu Tang, Tianwen Li
Summary: To study the heat transfer characteristics of R410A in extreme environments, the performance of various stainless steel and copper-enhanced tubes was evaluated using R410A as the working fluid. The results were compared with smooth tubes. The EHT-HB/D tube showed the best overall condensation heat transfer characteristics. The thermal conductivity of the tube (comparing stainless steel and copper) also affected the thermal hydraulic performance of the tube.
Article
Materials Science, Multidisciplinary
Mohamed Naguib Elkot, Binhan Sun, Xuyang Zhou, Dirk Ponge, Dierk Raabe
Summary: This study focuses on the hydrogen embrittlement behavior induced by kappa-carbide precipitation in high-Mn and high-Al lightweight steels. The presence of nanosized grain boundary kappa-carbides at early stages of aging is observed, and this phenomenon is correlated with the deterioration of hydrogen embrittlement resistance. The facile hydrogen-induced decohesion of grain boundary kappa-carbide/matrix interfaces is proposed as the mechanism for intergranular fracture. Other plasticity-associated hydrogen embrittlement mechanisms are also discussed, and possible alloying and microstructure design strategies for enhancing hydrogen embrittlement resistance are suggested.
Article
Thermodynamics
Wei Li, Hong Chen, Jiacheng Wang, Yu Gao, Xiaobo Wang, Yan He, Weiyu Tang, David J. Kukulka
Summary: Condensation heat transfer of R410A outside several enhanced heat transfer tubes (dimple/herringbone, herringbone, and dimple) and smooth tube was evaluated. The study found that the herringbone tube effectively improved the flow condensation performance outside the tubes, while the dimple-only structure was ineffective. The composite surface, produced by combining dimple and herringbone microfin patterns, showed substantial enhancement due to the liquid drainage effects and turbulence caused by the two structures.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2022)
Article
Thermodynamics
Qiang Gao, Yuhua Pang, Qi Sun, Dong Liu, Zhe Zhang
Summary: A comprehensive CFD model was developed to simulate gas flow, combustion, and heat transfer in a roller-hearth reheating furnace with radiant tubes, achieving good agreement between predicted slab temperature and experimental results. The model evaluated the temperature field in the furnace and the slab heating process, providing insights for optimizing the reheating process.
CASE STUDIES IN THERMAL ENGINEERING
(2021)
Article
Thermodynamics
Qiang Gao, Yuhua Pang, Qi Sun, Dong Liu, Zhe Zhang
Summary: The study of flow characteristics, combustion, and heat transfer in a heat treatment furnace is crucial for understanding temperature distribution. Three-dimensional CFD models were developed to simulate these processes. A novel transient CFD model was used to investigate slab heating characteristics, showing good consistency in results with different reaction mechanisms and proposing a pulse combustion method. The simulation results validated the model's accuracy in predicting temperature distribution.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2021)
Article
Chemistry, Physical
Auezhan Amanov, Joo-Hyun Choi, Young-Sik Pyun
Summary: The study investigated the effects of UNSM technology on the tribological properties and scratch-induced adhesion behavior of KHR 45A steel. It was found that UNSM treatment can improve friction coefficient, wear rate, and critical load, enhancing the adhesion behavior of the steel.
Article
Engineering, Mechanical
Willy Ank de Morais, Railson Bolsoni Falcao, Mario Boccalini Jr, Fernando Jose Gomes Landgraf
Summary: This study compares the fatigue behavior of bcc Nb-48 wt%Ti (Ti-36at%Nb) alloy parts processed by Laser Powder Bed Fusion (L-PBF) using two different types of powders (spherical powder produced by Plasma Atomization and irregularly shaped powder produced by Hydride-Dehydride). The results show that the fatigue behavior is similar for both powders, but the specimens produced from the Hydride-Dehydride powder have higher dispersed results. Fracture primarily occurs in the porosities near the machined sample surface, and the fatigue cracks propagate in a zigzag mode parallel to the L-PBF building direction.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Guoxi Jing, Shuai Sun, Teng Ma, Shubo Li, Tian Ma, Junchao Wei, Jianchao Pang
Summary: This study proposes a parameter identification method for predicting the TMF life of CGI materials used in cylinder heads. The study evaluates the TMF behavior of RuT450 material and successfully predicts its TMF life using multi-objective optimization. The results highlight the influence of plastic strain amplitude, temperature, and strain rate on the damage mechanism and life prediction.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Xin Zhang, Xu Li, Weipeng Xu, Kuidong Gao, Kao Jiang, Xinyu Wang, Hongxin Wei
Summary: Conical picks are commonly used in tunnel excavation and often experience high temperatures during the cutting process. This study investigated the influence of temperature on the wear of conical picks and proposed a method for measuring rock abrasiveness that takes into account the thermal effect. The experimental results showed that cooling liquid reduced the maximum temperature and the mean mass loss of the conical pick. Additionally, the study examined the characteristics of oxygen and found evidence of peeling, cracking, and oxidation on the grinding rod used for rock abrasiveness measurement.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Vivek Srivastava, Deependra Singh, A. G. Rao, V. P. Deshmukh
Summary: Engine gear failures are a significant concern in various industries. Investigating each gear failure and determining the root cause is important for preventing future failures. This study used experimental and numerical analysis techniques to investigate the premature failure of a flywheel gear in a marine diesel engine. The findings revealed that the gear failed due to overload stresses caused by overload torque generated from sudden inertial thrust in the internal combustionengine.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Jun Zhang, Weidong Liu, Feilong Liu, Zhiqiang Yang, Jinfang Peng, Minhao Zhu
Summary: During a major overhaul of an aeroengine, a cracked stator vane of the low-pressure compressor was discovered, with the crack originating from a corrosion pit located on the arc transition between the leading edge and the upper edge plate. The fracture surface exhibited signs of fatigue cracks, indicating a pit-related fatigue crack. Metallographic examination revealed that most corrosion pits were distributed beneath the bulging or peeling paint layer on the leading edge and the concave side. Identification of the corrosion products showed the presence of sulfate and alumina, suggesting atmospheric corrosion as a likely cause for the cracked stator vane.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Juan Jose Jimenez de Cisneros Fonfria, Ester Olmeda, Susana Sanz, Maria Garrosa, Vicente Diaz
Summary: Energy absorbing devices in vehicles can partially transform impact energy and protect passengers. In this paper, the failure analysis of the underframe crumple zone in a train car was conducted through finite element simulations, showing that the component acted properly after the impact.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Fengqi Zhang, Gang Luo, Haiyang Zhang, Peihong Cong, Lulu Liu, Wei Chen
Summary: In this study, a predictive model for bird strike trajectory was developed based on the quasi-linear viscoelastic model. By combining simulation analysis under multiple conditions, the model reproduced the trajectory change law in low and medium speed bird impact experiments.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
S. M. de Gouveia, L. de Abreu Correa, D. B. Teles, M. Oliveira, T. G. R. Clarke
Summary: Emergency Shutdown Valves (EDSVs) are used in industrial applications to interrupt fluid flow during hazardous events. The damage to the valve seats can be detected by analyzing the pressure and torque data. This study compared three processing options and found that evaluating the complete signature with a Gradient Boosting Classifier algorithm is the most effective strategy.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Xinyan Jin, Kai Wang, Hongwei Qian
Summary: This study investigated the root cause of an abnormal premature groove-clogging failure on a sink roll in a hot-dip galvanizing line. It was found that the failure was caused by the buildup of a large amount of Fe2Al5Znx dross in the grooves, and the key factor was the control of Tstrip.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Zhiqiang Li, Jie Li, Cen Li, Xiaodong Xie, Zhiyong Yang
Summary: In this study, the microstructure evolution of the material in the hot spot area of the high-speed train brake disc was observed and the mechanism of mechanical property degradation was obtained through tensile tests. The research results provide guidance for crack damage identification of the brake disc and condition-based maintenance.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Lijia Luo, Yincheng Wang, Wei Chen, Zuming Zhao, Wenfei Chen, Shiyi Bao
Summary: Tube-to-tube impact wear is a significant factor in the failure of alloy 690 tubes in nuclear steam generators. This paper investigates the wear damage mechanism and detection method of alloy 690 tubes under tube-to-tube impact loads. The results reveal the wear damage mechanism through analysis of macro and micro morphologies as well as metallographic structures. A nonlinear ultrasonic wave mixing method is proposed for damage detection and a detection device is developed to implement this method. Experimental results indicate that the damage mode of tube-to-tube impact wear varies with impact load and cycle number, and the nonlinear modulation index is effective in assessing the damage degree of alloy 690 tubes.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Xing-Ju Yang, Feng Lin, Xu Du, Lu Qiu
Summary: This paper proposes a novel method of improving the progressive collapse resistance of RC frame structures by adding locally debonded kinked steel plates (KPs). Experimental tests and finite element analysis reveal that the addition of KPs significantly enhances the ultimate resistance and deformability of the beam-slab substructures. The mechanism of resistance improvement is explained, and an analytical model is developed for predicting the ultimate resistance of the structures.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Xiaohe Wang, Zengqiang Cao
Summary: This paper presents a dynamic installation (DI) method based on electromagnetic force to reduce damage to composite laminates and improve joint performance. The study shows that DI can effectively decrease installation resistance, reduce severe damage to laminates, and improve stress distribution in the joint.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Jitong Cui, Yingying Kong, Cuiwei Liu, Baoping Cai, Faisal Khan, Yuxing Li
Summary: This paper presents a method for quantifying the failure probability of hydrogen doped pipelines and utilizes Bayesian network for quantitative calculation. The results show that this method can more accurately assess the failure probability of hydrogen doped pipelines and provide a decision basis for preventing failure accidents.
ENGINEERING FAILURE ANALYSIS
(2024)
Article
Engineering, Mechanical
Yiping Jiang, Maoru Chi, Jungang Yang, Liangcheng Dai, Yuchen Xie, Zhaotuan Guo
Summary: This article investigates and simulates the derailment of empty freight trains at the switch section of a turnout in the diverging route, and proposes preventive measures. The results show that the derailment is caused by the combined effect of various factors, and reducing the longitudinal coupler force and the wheel rail friction coefficient can decrease the possibility of derailment. Additionally, installing a guard rail in front of the turnout can effectively prevent derailment.
ENGINEERING FAILURE ANALYSIS
(2024)