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BRC-CORP 37-74.F % e e e %@ Section 21. GRAPHITIZAT Definition of the Problem Graphitization of carbon and carbon-nolybdenum steels is a Process in which iron carbides decompose into free iron (ferrite) and carbon (graphite). This decomposition is both tenperature and time dependent and occurs generally at temperatures between approximately 450°C (842°F) and 620°C (1148°F). The graphite nodules often tend to form preferentially along the low temperature edge of weld heat affected zones. When graphite segregation is associated with a high degree of graphitization, the graphite particles can form essentially continuous surfaces ("eyebrow gtaphitization) in heat affected zones and render the weldment susceptible to cracking. When the graphite nodules are distributed uniformly. as in plate or tube material, avay from weld zones, the cracking potential is low. However, uniformly graphitized steel typically possesses somewhat. lower strength than does the sane steel when new. Graphitization susceptibility has been found to be great steels which have been aluminum killed. ein Discussion of the Problem Although the severe "eyehrou" form of graphitization is encountered only rarely, it has occurred in steam power equipnent (Figure 21-1). Less severe graphitization has been found in a number of refinery applications, such as carbon steel catalytic cracking unit reactors, heater tubes, and transfer piping. Figure 21-2 shows a partially graphitized weldment, in which graphite is distributed randomly in a parent metal, and is also concentrated (but not continuous) in the low temperature portion of the neat affectea zone. ‘The microstructure of a typical graphitized carbon steel is shown in Figure 21-3. Methods of Checking for the Proble Determining with accuracy whether a steel has been graphitized can be accomplished only by metallographic examination, either on samples removed from the item or in place. After it has been established that graphitization has occurred, it is important to ascertain its extent. Metallographically, this can be secompliched by semparing the microctructusee with @ series vf plivevmletu= graphs prepared by Battelle Memorial Institute which represents the following arbitrarily chosen graphitization severity categories: Severe, Moderate-Severe, Moderate, Slight-Moderate, Slight, and Very Slight. Although these classifications lack precision in defining extent of graphitization, they do provide the metallurgist with a qualitative basis for describing the degree of graphitization observed. 7 100 BRC-CORP 37-74.F If considerable graphite is observed in a weld heat affected zone, it is usually desirable to determine if a sample taken transverse to the weld can withsrand an ambient tamperature bend tece. Severely graphitized heat affected zones may not bend without cracking. Methods of Eliminating the Problem In addition to preventing graphitization by avoiding the temperature range in which it occurs, a small concentration (about 12) vf chromium added to carvon or carbon-molybdenum steels is effective in inhibiting graphitization. Avoidance of aluminum as a deoxidizer in steel manufacture is recognized as an effective means of reducing edonificantly, but not neccooartly elininating, eunceytibility Lo graphitization. Pitfalle Because graphitization tendency appears to be related closely to steel composition, one cannot sample a large item of operating equipment. fabricated from many’heats of steel, in one location only, and expect to learn if graphitization has occurred anywhere in the equipment and, if sv, how severe 1t 1s. One should examine a variety of sample sites, involving @ uuuber Uf Wests Of steel, Co determine it graphitization is a problem in a specific application. : : : : : : BRCCORP 37-74. 101 S OOOO OOCOOHOOCHEOOOOOD Figure 21-1, Eyebrow Type of Graphitization Adjacent to » Wald in Carbon Stee! Magnification: 4X. e e e e e e e e e e e e e e e 102 Figure 212 Pertally Graphitized feldment in Carbon Steel ‘Magnification: 2X. BRCCORP 37-74. °e BRC-CORP 37-745 Figure 213. Photomicrograph of Typical Graphitization in Carbon Steel Weldment ‘Magnification: 100K. 103

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