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1. Introduction
The paper presents the degradation state assessment for a weld metallic structure using the
nondestructive metallographic replicas method. The components subdued under duration
loadings, thermal and mechanical sustain microstructure degradation in service period,
degradations that will finally lead to failure.
The thermo mechanicals loads conduce to apparition of creep phenomenon which
conduces in time to microstructure modification, the carbide increase and distribution in
inside and to grains limit, affecting the strength characteristics of the material. To analyse
these type of structure modification can be used metallographic replicas methods. In
general, metallographic replicas can be used for:
(a) microstructure study (creep cavities, grain size etc.) using the surface replicas
and optical microscopy;
(b) examination and identification of small secondary phase particles from
extraction replicas techniques in order to determine the distances between particles.
1.1. Surface replicas
Replicas can provide information on the current status of the material they are made the
components. The method is nondestructive and can be applied in any area accessible of
structure. The replicas providing only relevant data to the component surface examined.
Standard procedure
This procedure defines the requirements for making adequate surface replicas for
metallographic examination. This procedure can be successfully applied in assessing the
microstructure of components working at high temperatures in creep area, according to
ASTM E 1351-01 [1].
Interpretation
Surface replicas are suitable to examination with an optical microscope with a
magnification of 500 times. If the examination is performed using a transmission electron
microscope, are necessary specific replicas partly immersed in acetone. Dissolution of
acetate film leads to a positive replicas image for examination under a microscope [2].
Nordtest
VGB-TW 507
2a, 2b
3a , 3b
0/1 , 1
1/2 , 2
2/3 , 3, 3/4
ISQ
ND
NU + ND
(1)
The length of the traverse (L) and the grain size, defined by the mean linear intercept, l,
calculated:
l = L / (NU + ND)
(2)
1
4
LF = 1 1 A
(3)
and
1 LF
t reman = t serv
LF
where:
- LF = life fraction consumed = tserv/tr
- A = number fraction of cavitated grain boundaries, measured on a line parallel to
the principal stress axis;
- n = stress exponent for creep;
- = primary hardening exponent;
- = r/s;
- r = creep rupture strain;
- s = mtr = Monkman-Grant parameter;
m=minimum creep rate
- tr = creep rupture life;
- tserv = service life to date.
3
(4)
If the damage is uniform through the section, then this time is the time to failure, if the
damage is localised, this time is the time to crack initiation.
Values of the parameters n, are dependent on material, stress and temperature.
Material:
Inside Diameter:
D = 6200 mm
V = 697000 litres
Sp = 25 mm
C1 = 3 mm
PS = 0,5 MPa
Operating Pressure:
0,4 MPa
1,45 MPa
TSmax = +485C
TSmin = +15C
Tmax = +475C
Tmin = +30C
1415 cycles
72.600hours
References:
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