Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ANALYSIS
REPOR
T
Case Study
Group 1
StudBolt Failure
dueto
Hydrogen
Embrittlement
TechnicalRepor
t
MetallurgyandMaterialDepartmentmakesnorepresentationsorwarranties,eithe
r expressedorimplied,
andspecificallyprovidestheresultsofthisreportasisbasedon
theinformationprovidedbyclient
Executive Summary
PT.SulzerTurboServicesIndonesiareportedthatitsstudbolthad
failedinservice.
AsreportedbyPT.SulzerTurboServicesIndonesia,thefailure
occurredonthe
to
hydrogenembrittlementthatresultedfromitslongexposureto
atmosphere
duringoperation.
oflocalizedprecipitatesinthe
Thepresenceofthe
failedstudboltacceleratedthe
hydrogengas
areawitha
number
failurebecausethis
and then
bondingbetween
metalatoms.As
aresult,thestudbolt
materialfracturedin
brittlemode.Inmostcases,oncethehydrogengasis
formedinthemetalandandweakensthemetal atombonding,thecrack propagationwould
occurautomatically withoutthe external stress becausethis produced hydrogen has
enough pressureto create andpropagate thecracks.
Background Information
PT.
SulzerTurboServicesIndonesiareportedthatitsstud
service.AsreportedbyPT.SulzerTurboServicesIndonesia,the
bolthad
failedin
failureoccurredon
failedpartonly
occurredononeendofthestudbolt.Principally,theboltis
application.Figure1illustratesthe
principalworkof
studboltinjoiningmethod.ThefailedsamplewasthensubmittedtoCMPFAfor
failure analysis(Fig. 2).
Objectives
The assessmentwas carried out in Metallurgyand Material Department,
University
ofIndonesia,inordertofindouttherootcausefailureofstudboltandto
make
recommendations.
Thescope ofwork wasasfollows:
1. .
2.
3.
4.
InvestigationResults
Visualexamination
The failedstud bolt was visually
condition(Fig.1).Forabetter
examined
and photographed in
as-received
examination,thefracturesurfaceofthefailedstudbolt
wasobservedbyopticalmicroscopeatmagnificationof7X(Fig.2).Asobserved
fromthemacrophotography,thecrackseemstobeinitiatedfromaspotatthe
threadandtopropagateinacircumferentialmode.Thecracksurfacehadawide
smooth area(crackpropagationroute) androugharea(final rupture).
Chemical
Test
Inorder
Composition
toobtaininformation
aboutthechemical
subjectedtothechemicalcompositiontest
composition,thesamplewasthen
usingOptical
EmissionSpectroscopy
(OES).Table1showsthechemicalcompositionoffailedsamplein
comparisonwith
andtheoneinthestandard.
Thetested
material(3.0-5.0%Ni).Theother
materialrequirement,
as
elementscomply
canbeseeninthetable.Thisslight
Tensile Test
The tensiletest was
conducted to
mechanical
propertiesofsampleincomparisonwithASTM
A564Grade630.
material.Itsyieldstrengthis1225MPa,whichis55MPahigher
overthestandard
materialanditselongationis
than
10.86%(0.86%higherthanthe
standardmaterial.
Hardness test
Toobtainanother
mechanical
propertiesinformation,hardnesstestwasperformed
onthefailedsample.Table3showsthehardnessvalueofsampleincomparison
withASTMA564Grade630.Theresultshowsthatthehardness
theminimumvaluerequiredby
valueisslightly
thestandard.Thefailedsamplehasa
below
hardness
Metallographicanalysis
Themetallographictestwascarried out onthecross sectionofthefailed thread.The
testwasinaccordancewithASTME3
forthemetallographicpreparationtoobserve
thegrainofthetestedmaterial.Thesamplewas etchedusingAquaRegiasolution.
Informationobtainedfromthe
microstructure
photosisthat
studboltcontainsmartensitephases.Thecrackpropagating
the
basematerialofthe
along
thegrain
fracturesurface
wasobservedusingScanningElectronMicroscopy
(SEM)to
TheEDSanalysiswasalsoperformedonthe
fracturesurface
analyzeanypossiblecontributionofenvironmentormicrophaseofthematerialto
to
the
failure.Thecrackpropagatingfromthethreadwasobservedonboththefracture
surfacesofthefailedsample.Figure 8 and9 showthe propagatingcrack.
The
fracturesurface
sincenoevidence
indicatethat
observed
fromSEMimagesindicatesthatitisbrittle
ofdimpleslocatedinthe
the
fracturemodeisductile.
transgranular.Intergranularbrittle
thegrainboundaries.
fracturearea.
fracture
Thepresencesofdimples
Brittlefracturecanbe
intergranularor
fracturecanbetheresultofembrittlement
along
Precipitateswerefoundwithinthematrixofbase
hardenedstainlesssteel;itmainly
composed
metalsinceitisaprecipitateofFe-Cr.Butan
thattheprecipitateswithinthefailedsamplewereconcentratedat
anomalywasfound
onepoint.Some
Based
ontheEDSresultsshowed
onTable
4and5,thecompositionofFe
andCr
areintroducedtogivestrengthtothematerial.
Some
disadvantages
arethenfoundiftheyarenotwelldispersed(inhomogeneous).
The accumulated precipitates could generate weak areasincestress concentration
willbelocatedonthatspot.Thiswillbetheinitialspotforfatiguecrackpropagation.
Afatiguecrackwilltypicallyinitiateatadiscontinuityinthematerialwherethecyclic
stressismaximum.Sincethestudboldexperiencedthetensilestressandalso
vibrationduringapplication,thecombinationoftensilestressandvibrationcould
facilitate thefatiguefailure tooccur..
Discussion
Thestudboltiscommonly usedasa fastener tojointwoparts altogether;thepart suchas
flangeisjoinedusingthiskindofbolt(seeFig.1).Based
compositiontest(see
Table1)
thestud
onthechemical
andmetallographicexamination(seeFig.
5,6&
7),
boltwasmadeofprecipitated-hardenedstainlesssteel
withmartensitephasematrix.TheEDSimage
analysis
results
showed
thattheprecipitates(seeFig.
11) mainly composed ofFe-Crthatcame fromthealloying elementsofthestainless
steel.Inpractice,whenthenutisfastened,astress(tensile)isthenintroducedto
thestudbold.
Sincetheboltwasapplied
onaturbine
part,thevibration
during
operationcouldbealsotransferredtotheboltgeneratingacyclicload.
its
The
combinationbetweenatensilestressandavibrationcouldpossiblytriggerthe
fatiguefailure.
Theboltswereappliedontheturbinesystemconsumingfuelmainlycomposed
nitrogen(N2)andhydrogen(H2)withsmall
of
fractionofargon(Ar),methane(CH4),
carbondioxide(CO2)andcarbonmonoxide(CO).Thecorrosivegasinthissystem
isCO2.However,stainlesssteelisrelatively
resistanttoCO2corrosion.Noevidence
Themechanicalproperties(seeTable2&3)test
showedthatthe
tensilestrengthandhardnessofthefailedsampledidnotconformtotheASTM
A564Grade
material,leadingtoa
whenitwastested.A
new
andEDSto
obtaininformationaboutthecracksurface.Based
Thecrackspropagatedintergranularlyalong
boundarygeneratingthebrittle
(Backscattered)
image,
fracturemode(seeFig.5&
thegrain
6).BasedontheBSD
precipitateswerefoundinhomogeneouslydispersedwithin
thethread(seeFig.
14);someprecipitateswereaccumulated
generating
stress
forcrackinitiationsinceamaximumstresswillbemainly
focusedonthoseparticleswhenthestressis
effectwillbecatastrophic
ifthe
workinginthe
precipitatesare
bolt.BasedontheSEM
accumulatedat
material;
accumulated
or
moreover,this
atcertainspotonthe
observation,anumberofprecipitates
duetocyclic
load(fatigue).Nevertheless,it
mightbe
notindicatingthat
fatiguewastherootcauseofthefailure.Itwaspossiblytriggeredby
otherinitiation
duetohydrogenwas
SEMimages,thecrackspropagated
dimplewere
also
observed.Based
alongthegrainboundary.
onthe
Noevidences
observedonthsductilematerialthusindicating
of
thatthecracks
propagatedduetoembrittlement(seeFig.15).Theatmospherecontainshydrogengas(H2)
thatpossiblybethesourceofhydrogenatomsdiffusingintothemetal
matrixcreatingembrittlement.
othergases
may
beconsideredasthe
Severalliteratureshavereportedtheeffectsofhydrogenembrittlement
gaseousimpurities.Gasimpuritiescaninhibit,accelerate,
hydrogenembrittlement.Asdocumentedelsewhere,CH4
of
orhavenoeffectupon
andN2
gaseshaveno
exposureofthemetallikethestud
bolttothehydrogengasinthecontainer
could
promotethehydrogenatomsto
migrateintothemetalmatrix.Someofthehydrogenatomsre-combinedwithcarbon atoms
toformmethane
gas(CH4)inside
methanegascreatedpressurewithinthe
thatcouldreducetheductility
withintheminuscule
ofa
minusculevoids(see
Fig.17)
metalcreatingembrittlement.Not
voidswherehydrogenwaspresentbut
boundariessincetherewerealsocavitiesdue
direction.
minusculevoids.The
tothedisorder
also
only
withinthegrain
arrangementofatomic
Thefailedstudboltwasexposedtotherelatively
hightemperature
Accordingtotheliterature,underambient
(around160C).
temperature,hydrogenatomscanbe
underthisconditionwillpropagatetransgranularly.Otherwise,
hightemperature,theabsorbed
under
hydrogenatomstendtogatherinthegrain
boundariesandthecrackswill
propagateintergranularly[4].Someresearchers
[8].Inthecaseofthis
failedstudbolt,the
areawiththe
projectteamin2004statesthatthe
hydrogenstorage
maximumworking
pressure
systemis103Mpa,whichismuchhigherthantheactualworkingpressurein
system,i.e.
around6Mpa(around60Bar).
Thus,thereis
forthis
Sulzers
noissueof
overpressurecontributingto thefailure.
Conclusion
Thestudboltfailed duetohydrogenembrittlementthatresulted fromitslong exposureto
hydrogengas
atmosphereduring
operation.Thepresence
withanumberoflocalizedprecipitatesinthefailedstudbolt
becausethislocalizedprecipitates
moleculesthat
acceleratedthefailure
wasthemostfavorablesitefor
camefromtheinnercontainertore-combined
ofthearea
hydrogen
andthenproducedthe
betweenmetal
atoms.Asaresult,thestudboltmaterial
brittlemode.Inmostcases,oncethehydrogengasisformedinthe
andandweakensthe
metal
metal
atombonding,thecrackpropagationwouldoccur
Recommendations
1. Usethematerial withtheunwantedprecipitates as lowas possible.
2. Athouroughmaterial selectionstudyalongwith thelaboratorytestare
commonlyrequiredforthematerials thatwould becontinuouslyexposedto
hydrogengas.
Reference
1. FatigueFailure ResultingfromVariableLoading(http://highered.mcgrawhill.com/sites/dl/free/0073121932/365766/chapter06.pdf )
2. Fractography,ASM Handbook Vol 12,ASM International,OH.
3. http://www.corrosionist.com/hydrogen_embrittlement_stainless_steels.htm
4. http://events.nace.org/library/corrosion/Forms/embrittlement.asp
5. http://www.contech.com/Failure_Analysis.htm
6. Barthelemy,H.EffectsofPurityandPressureonTheHidrogenEmbrittlement ofSteel
andOther Metallic Materials. AirLiquide.
7. http://events.nace.org/library/corrosion/Forms/embrittlement.asp
8.http://www.ehow.com/info_8402999_effects-hydrogen-embrittlementsteel.html
9. Greenslade,Joe.2005.HereisWhataHidrogenEmbrittlementFailureReally
LooksLike.Distributors LinkMagazine,Spring
10.Jinyang, Zhenget al. 2012. Development ofHigh Pressure Gaseous
HydrogenStorageTechnologies.ScienceDirect.